Safe Air Entry systems represent a critical component in modern industrial safety architecture, combining energy isolation, air preparation, and safe exhaust capabilities into fully integrated, pre-engineered panel-mounted assemblies. These systems are specifically engineered for pneumatic control and air dump/release applications where worker safety, regulatory compliance, and operational efficiency are paramount.

What's Inside the Safe Air Entry M35 Series Catalog

This comprehensive catalog provides detailed specifications, configuration options, selection guidance, and technical data for complete Safe Air Entry assemblies. The catalog is structured to serve multiple audiences—from safety engineers conducting risk assessments to maintenance personnel installing and servicing pneumatic safety systems.

Key Catalog Sections Include:

Product Overview and Applications: The catalog opens with a detailed explanation of Safe Air Entry system functionality and typical industrial applications. You'll understand how these pre-engineered systems integrate lockout/tagout (LOTO) capabilities, air filtration/regulation, and Category 4 PL e safe exhaust valves into a single, tested assembly ready for installation.

M35 Series Double Valve Technology: Detailed coverage of the M35 Series externally monitored double valves that form the heart of these safety systems. The catalog explains the proven ROSS SERPAR® Crossflow technology, dual poppet design, and how these valves achieve up to 99% diagnostic coverage through external monitoring of solid-state pressure sensors on each valve element.

System Component Breakdown: Comprehensive descriptions of every component in Safe Air Entry assemblies, including manual Lockout L-O-X® valves (both Classic and Modular series), air preparation equipment (filters, regulators, lubricators with metal bowls), M12 electrical connections, pressure gauges (analog and digital transducers), port blocks, silencers, and optional drip leg assemblies.

Configuration Options: The catalog presents two primary assembly types—Type C configurations featuring Classic Lockout L-O-X® valves with side-by-side filter and pressure regulator units with metal bowls, and Type M configurations with Modular Lockout L-O-X® valves and integrated filter/regulator units with high-strength polycarbonate bowls.

M35 Series Double Valve Features and Specifications

The M35 Series double valves represent the latest evolution in pneumatic safety technology, and this catalog provides exhaustive technical detail on their capabilities:

Safety Performance: The catalog documents how M35 Series valves achieve Category 4, PL e classification, meeting the most stringent safety requirements for machinery applications. Each valve features redundant 3/2 normally closed functionality with dual poppet construction and external monitoring capability that provides diagnostic coverage up to 99% when both solid-state pressure sensors are monitored during every actuation and de-actuation cycle.

Mechanical Design Excellence: Detailed specifications cover the dirt-tolerant, wear-compensating poppet design that delivers quick response times and high flow capacity. The catalog explains how PTFE backup piston rings enhance valve endurance, enabling reliable operation with or without in-line lubrication—a critical consideration for diverse industrial environments.

Optional Soft-Start Module (EEZ-ON®): The catalog thoroughly documents the optional soft-start functionality, explaining how on energization, outlet pressure increases at a controlled rate until reaching approximately 50% of inlet pressure, then opens fully to complete system filling. This feature prevents sudden pressure surges that can damage equipment or create unsafe conditions.

Modular Connectivity: Technical drawings and specifications show how M35 Series valves feature modular port connections enabling direct integration with Air Entry System components including Lockout valves and FRL assemblies, reducing installation complexity and potential leak points.

Visual Diagnostics: The catalog details the integrated LED indicators that provide real-time visual display of valve status, significantly aiding troubleshooting and reducing mean time to repair (MTTR) during service events.

Technical Specifications and Performance Data

The catalog provides comprehensive technical specifications essential for proper system selection and application:

Operating Parameters:

• Operating pressure range: 30 to 150 psi (2 to 10 bar)
• Ambient temperature range: 40° to 120°F (4° to 50°C)
• Media temperature range: 40° to 175°F (4° to 80°C)
• Flow media: Compressed air according to ISO 8573-1 Class 7:4:4
• Mounting: Inline mounted with modular or threaded connections
• Mounting orientation: Any orientation, vertical mounting preferred

Flow Capacity Data: Detailed flow coefficients (Cv) for various port sizes:

• Port sizes available: 1/2" and 3/4" inlet/outlet configurations
• Ports 1-2 Flow: 4.1 to 4.3 Cv (4034 to 4231 Nl/min) depending on configuration
• Ports 2-3 Flow: 7.57 Cv (7449 Nl/min) for rapid exhaust capability

Electrical Specifications:

• Standard voltage: 24 VDC
• Power consumption: 2.0 watts per solenoid
• Solenoid connection: 5-pin M12 connector
• Feedback connection: 5-pin M12 connector
• Feedback sensors: PNP solid-state pressure sensors
• Sensor rating: 5 amps at 250 volts AC or 5 amps at 30 volts DC
• Multiple pin configurations available (AA, AB, AC, DB, DC, etc.)

Physical Dimensions: The catalog includes precise dimensional drawings with height, length, width, and weight specifications for each configuration, essential for panel design and space planning.

Lockout/Tagout (LOTO) Integration and Safety Standards Compliance

A substantial portion of the catalog addresses lockout/tagout requirements and how Safe Air Entry systems facilitate OSHA and ISO 14118 compliance:

Energy Isolation Principles: The catalog explains how manual Lockout L-O-X® valves serve as energy isolation devices (not emergency stop devices), providing the first line of defense in a comprehensive pneumatic safety system. These valves block the supply and rapidly exhaust downstream pressure, enabling safe machine access for maintenance and servicing.

Classic vs. Modular Lockout Technology: Detailed comparison of Classic and Modular L-O-X® valve series, including:

• Unique identification features (yellow body, red handle)
• Lockable-only-in-OFF-position design preventing inadvertent energization
• Full-size exhaust ports (equal to or larger than supply) for rapid downstream air evacuation
• Fluorocarbon slipper seals ensuring easy operation even after extended inactivity periods
• Integrated sensing ports for pressure verification with visual pop-up indicators or electrical pressure switches

Compliance Documentation: The catalog provides reference information for relevant safety standards including EN ISO 13849-1, EN ISO 13849-2, OSHA 1910.147 (Control of Hazardous Energy), and machinery directive requirements (2006/42/EC).

Air Preparation Components and FRL Systems

The catalog dedicates significant coverage to air preparation equipment integrated into Safe Air Entry assemblies:

Filter Technology: Specifications for inline filters with metal bowls designed to remove particulate contamination, water condensate, and other contaminants that can damage downstream components or compromise safety valve performance. The catalog explains filtration ratings and maintenance intervals.

Pressure Regulation: Detailed information on integrated or side-by-side pressure regulators that maintain consistent downstream pressure regardless of supply pressure fluctuations. Pressure regulation is critical for achieving predictable actuator performance and maintaining safety system integrity.

Lubrication Systems: For applications requiring lubricated air, the catalog covers optional lubricator units with metal bowls, including proper oil selection guidelines and fill/maintenance procedures.

Filter/Regulator Combination Units: The catalog compares integrated F/R units (compact design with polycarbonate bowls) versus side-by-side FR configurations (metal bowls, easier individual component service), helping engineers select the optimal configuration for their application requirements.

System Configuration and Customization Options

One of the catalog's most valuable sections guides users through available configuration options:

Port Size Selection: Guidance on selecting appropriate port sizes (1/2" or 3/4") based on flow requirements, actuator sizes, and system response time requirements. The catalog includes flow calculation examples and pressure drop considerations.

Thread Type Options: The catalog details available thread types—G (BSP parallel) and NPT (American National Standard Pipe Thread)—with application guidance for international markets and existing piping infrastructure.

Gauge Options: Comparison of analog pressure gauges versus digital pressure transducers, including accuracy specifications, visibility considerations, and integration with SCADA/HMI systems for remote monitoring.

Extra Port Block Configuration: Documentation of optional extra port blocks (1/4" and 3/8" sizes) that can be positioned upstream or downstream of the main assembly, providing convenient connection points for pilot air supplies, pressure switches, or auxiliary equipment.

Exhaust Options: The catalog covers built-in silencer modules for noise reduction in the immediate vicinity versus threaded flanges for remote exhaust line connection when noise must be directed away from work areas.

Optional Drip Leg Assemblies: For applications with high humidity or contamination concerns, the catalog details drip leg configurations featuring inlet and drain ball valves that enable condensate removal upstream of critical components.

Installation, Commissioning, and Maintenance Guidelines

While the full installation instructions are referenced as separate documents, the catalog provides essential overview information:

Pre-Installation Requirements: Checklist of supply air quality requirements (ISO 8573-1 compliance), electrical power specifications, mounting surface preparation, and environmental considerations.

System Testing Procedures: Overview of functional safety validation testing required before initial operation and as part of ongoing safety system verification programs. The catalog references SISTEMA software library availability for safety integrity calculations.

Preventive Maintenance: Recommended inspection intervals for filter elements, pressure regulator diaphragms, bowl drainage, and valve functionality testing. The catalog emphasizes that properly maintained systems deliver longer service life and more reliable safety performance.

Troubleshooting Quick Reference: Common operational issues, LED indicator patterns, and systematic diagnostic approaches that help maintenance personnel quickly identify and resolve problems.

Certifications and Global Compliance

The catalog prominently features certification documentation:

Safety Certifications: Detailed information about DGUV certification (German Social Accident Insurance testing), CE marking compliance with EU Machinery Directive, CSA certification for North American markets, and EAC Declaration for Eurasian markets.

Performance Ratings: Clear documentation of Safety Category 4, Performance Level e (PL e), and Safety Integrity Level 3 (SIL 3) ratings with reference to applicable standards and testing protocols.

SISTEMA Library Availability: The catalog references downloadable SISTEMA library files that enable safety engineers to incorporate verified M35 Series valve performance data into their safety system calculations per EN ISO 13849-1 requirements.

Application Examples and Industry Use Cases

The catalog includes practical application guidance across multiple industries:

Manufacturing and Assembly: Safe Air Entry systems protecting press operations, automated assembly cells, robotic work cells, and material handling equipment where worker interaction with pneumatically powered machinery creates potential hazards.

Packaging Operations: Applications in high-speed packaging lines where frequent access for changeovers, jam clearance, and adjustment requires rapid, reliable energy isolation and controlled system re-pressurization via soft-start functionality.

Automotive Production: Integration in body welding systems, paint shop pneumatic fixtures, final assembly tooling, and test equipment where Safety Category 4 performance is mandated by corporate safety standards and regulatory requirements.

Food and Beverage: Specifications for wash-down environments, including stainless steel component options, metal bowl FRL components, and mounting configurations that facilitate cleaning and sanitation protocols.

General Industrial: Applications in metalworking machinery, woodworking equipment, plastic processing, and other general industrial settings where OSHA compliance and worker safety are paramount.

Why Choose ROSS Controls Safe Air Entry Systems

The catalog articulates the value proposition of integrated Safe Air Entry assemblies:

Pre-Engineered Reliability: Unlike field-assembled systems cobbled together from disparate components, Safe Air Entry assemblies are factory designed, assembled, and tested as complete systems, ensuring compatibility and performance before shipping.

Time and Cost Savings: Reduced engineering time for component selection and system design, simplified procurement through single-part-number ordering, faster installation with modular connections, and minimized commissioning time with pre-tested assemblies.

Safety Integrity: Achieving Category 4 PL e safety performance requires proven component selection, proper integration, and verification testing—all provided in complete Safe Air Entry systems backed by ROSS Controls' safety engineering expertise.

Technical Support: The catalog emphasizes ROSS Controls' commitment to customer support, including application engineering assistance, safety system design consultation, training programs, and global service network access.

Ordering Information and Part Number Configuration

The catalog includes comprehensive ordering information:

Part Number Structure: Detailed explanation of ROSS Controls' part numbering system for Safe Air Entry assemblies, enabling customers to decode existing part numbers or construct new part numbers for custom configurations.

Lead Time Information: Standard manufacturing and delivery timeframes for common configurations plus custom-engineered assembly options requiring extended lead times.

Related Products: Cross-references to complementary ROSS Controls products including standalone M35 Series valves, replacement component parts, alternative safe exhaust valve series (DM1C, DM2C), and accessories.

Additional Resources and Technical Support

The catalog concludes with guidance on accessing additional resources:

Downloadable Documentation: References to installation instructions, operation manuals, SISTEMA library files, CAD models, electrical connection diagrams, and piping schematics available via the ROSS Controls website.

Training Opportunities: Information about ROSS Controls' technical training programs covering pneumatic safety principles, proper valve selection, installation best practices, and maintenance procedures.

Custom Solutions: Contact information for ROSS Controls engineering team for applications requiring custom assembly configurations, special certifications, or integration with existing equipment.

Who Should Download This Catalog?

This comprehensive technical catalog serves multiple professional audiences:

Safety Engineers and Safety Managers: Essential resource for risk assessment activities, safety system design, and specification of pneumatic safety components meeting Category 4 PL e requirements.

Control Engineers and Automation Specialists: Detailed technical data for integrating M35 Series valves with safety PLCs, safety relays, and other control system architecture.

Maintenance Engineers and Technicians: Specifications, troubleshooting guidance, and replacement part information for existing Safe Air Entry systems.

Machine Designers and OEM Engineers: Configuration options and dimensional data for incorporating Safe Air Entry assemblies into new machine designs.

Purchasing and Procurement Professionals: Complete part numbering information and specifications for accurate procurement of compliant pneumatic safety components.

Plant Managers and Production Supervisors: Overview of safety capabilities and operational benefits for capital equipment decision-making.

Download Your Free Catalog Today

Access the complete Safe Air Entry with M35 Series Double Valves catalog to explore:

✓ Detailed technical specifications for all configuration options
✓ Dimensional drawings and mounting information
✓ Electrical connection diagrams and wiring specifications
✓ Flow capacity data and performance curves
✓ Certification documentation and compliance information
✓ Application examples and system design guidance
✓ Part numbering structure and ordering information
✓ Maintenance recommendations and troubleshooting tips

This catalog represents decades of ROSS Controls pneumatic safety expertise distilled into a practical reference tool for specifying, installing, and maintaining industry-leading Safe Air Entry systems that protect workers, ensure compliance, and optimize operational uptime.

Frequently Asked Questions About M35 Series Safe Air Entry Systems

What is a Safe Air Entry system?
A Safe Air Entry system is an integrated pneumatic safety assembly combining manual lockout/tagout capability, air preparation (filtration, regulation, lubrication), and safe exhaust functionality in a pre-engineered, factory-tested package designed for rapid installation at the point of air entry to machines or zones.

What safety category does the M35 Series achieve?
M35 Series Safe Air Entry systems achieve Category 4, Performance Level e (PL e) per EN ISO 13849-1 and Safety Integrity Level 3 (SIL 3), representing the highest levels of safety performance for pneumatic control applications.

What is external monitoring in M35 Series valves?
External monitoring means each of the two valve elements contains a solid-state pressure sensor that must be monitored by an external safety control system (safety PLC or safety relay). By monitoring both sensors during every actuation and de-actuation cycle, diagnostic coverage up to 99% is achieved.

What is soft-start functionality?
Optional soft-start (EEZ-ON®) allows controlled pressure buildup when the system is energized. Pressure increases gradually until reaching approximately 50% of inlet pressure, then opens fully to complete filling. This prevents sudden pressure surges that could damage equipment or create unsafe conditions.

What are the differences between Classic and Modular L-O-X® valves?
Classic L-O-X® valves typically pair with side-by-side filter/regulator units with metal bowls, while Modular L-O-X® valves integrate with compact filter/regulator combination units featuring polycarbonate bowls. Both provide equivalent lockout/tagout functionality but differ in footprint and serviceability.