The safety function of the DM2® Series C valve is to shut off supply of pneumatic energy and exhaust any residual pneumatic pressure from downstream of the valve. Unlike standard pneumatic control valves, the DM2® Series C incorporates redundant control architecture with integrated dynamic monitoring, achieving the highest safety integrity levels demanded by modern manufacturing environments. The valve design provides a residual outlet pressure of less than 1% of supply pressure when locked out, ensuring workers are protected from unexpected energy release.

Key Features & Technological Advantages

Redundant Control Architecture The DM2® Series C features dual identical valve elements providing Category 4, PL e performance when used with proper safety controls. This redundancy architecture ensures that even if one valve element experiences a failure, the second element maintains safe operation, preventing catastrophic energy release scenarios that could result in worker injury.

Dynamic Monitoring & Asynchronous Detection Built-in dynamic monitoring continuously cycles through actuating and de-actuating movements, detecting any asynchronous movement between valve elements. If asymmetrical operation is detected, the valve automatically latches into a safe condition with minimal residual outlet pressure. This monitoring function has integrated memory requiring an overt reset action to restore normal operation after lockout—the valve cannot be reset by simply removing and reapplying supply pressure, eliminating the risk of accidental reactivation.

Poppet Design for Reliability The DM2® Series C utilizes a dirt-tolerant, wear-compensating poppet design enabling quick response and high flow capacity even in demanding industrial environments. The design delivers superior performance in unfiltered or contaminated air conditions, reducing maintenance burden and extending service life compared to traditional spool-valve architectures.

PTFE Backup Piston Rings Enhanced PTFE backup piston rings extend valve endurance and enable operation with or without in-line lubrication. This flexibility simplifies system design and reduces maintenance complexity while maintaining consistent performance across varied operating conditions.

Integrated Status Indicator A built-in mechanical pressure switch or solid-state pressure sensor provides real-time status feedback to the control system, indicating whether the valve is in lockout or ready-to-run condition. This critical feedback enables closed-loop safety monitoring and immediate alert to maintenance personnel if valve status changes unexpectedly.

High-Flow Silencer The included clog-resistant silencer reduces exhaust noise while maintaining full flow capacity. The high-flow design prevents the back pressure issues common with traditional silencers, ensuring the valve's energy exhaustion performance isn't compromised.

Base-Mounted Design Easy-to-replace base mounting with captive valve-to-base mounting screws simplifies maintenance and reduces downtime during valve replacement. The flexible piping design with inlet and outlet ports on both sides (supplied with plugs for unused ports) provides installation flexibility in space-constrained machine designs.

Intermediate Pilots (Sizes 12 & 30) Larger valve sizes incorporate intermediate pilot boosters that increase pilot air flow for exceptionally fast valve response. This design allows manufacturers to use the same electrical solenoid sizes as smaller valve configurations, significantly reducing electrical power requirements and system complexity.

SISTEMA Library Download Complete SISTEMA simulation library files are available for download, enabling engineers to model valve behavior and integrate the DM2® Series C into virtual commissioning environments for thorough pre-installation validation.

Safety Certifications & Compliance Standards

The DM2® Series C meets the most demanding functional safety requirements in industrial manufacturing:

ISO 13849-1:2015 Compliance Achieves Category 4 and Performance Level e (PL e) rating, the highest safety integrity classification for single-channel systems with diagnostics. This certification demonstrates compliance with international functional safety standards applicable across automotive, metal forming, packaging, and press machinery applications.

IEC 61061:2001 Safety Integrity Level (SIL) Rated for SIL 3 operation per the international standard for electrical/electronic/programmable electronic safety systems. This certification applies to systems used in applications where hazardous energy could result in serious injury or death.

TÜV-Certified Safety Component The valve holds TÜV certification (HM 230178) with "Sicherheit seprüft" (safety tested) designation, confirming independent third-party validation of safety performance. This certification is essential for facility audits, OSHA compliance documentation, and insurance carrier assessments.

Declaration of Conformity Complete CE Declaration of Conformity available, certifying compliance with applicable EU machinery directives and essential health and safety requirements. This documentation supports international market access and regulatory compliance pathways.

Vibration and Impact Resistance Tested to DIN EN 60068-2-6 specifications for vibration and impact resistance, ensuring reliability in harsh manufacturing environments with heavy equipment, presses, and mechanical vibration.

Technical Specifications & Operating Parameters

Functional Specifications

Available Sizes & Flow Capacities

Operating Conditions

Electrical Data

The DM2® Series C supports multiple electrical configurations for global installations:

Construction Materials

Functional Safety Data

Valve Operation Modes & Functional Behavior

Ready-to-Run (De-actuated) State In the ready-to-run position, restricted inlet air flow pressurizes pilot supply chambers, holding inlet poppets in the closed position. The valve is fully charged and ready to actuate upon solenoid command.

Actuated (Open) State Energizing the pilot solenoids applies simultaneous pressure to both pistons, forcing valve elements to the open position. Inlet air flows to the outlet chamber, and exhaust poppets close, allowing system pressurization. De-energizing pilots rapidly returns the valve to ready-to-run position.

Locked-Out (Failure Detection) State If valve elements operate asynchronously during actuation or de-actuation—indicating a failure condition—the valve automatically moves to a locked-out position. In this state, one crossover is exhausted while the other remains pressurized, creating a latching force that prevents further operation. Residual outlet pressure drops to less than 1% of inlet pressure, providing maximum worker safety. The valve remains in lockout even if supply pressure is removed and reapplied, requiring an explicit reset signal to restore normal operation.

Reset Operation Reset is accomplished by momentarily pressurizing the dedicated reset port, either through a remote 3/2 normally closed valve or integrated solenoid on the reset adapter. Actuation of the reset piston physically pushes main valve elements to their closed position, immediately exhausting pilot supply air to prevent accidental operation during reset. De-actuation of reset pistons restores pilot supply pressure and ready-to-run status.

Status Indicator Function The integrated pressure switch actuates during normal operation and de-actuates when the valve is locked out or inlet pressure is removed. This provides continuous feedback to the control system regarding valve status—critical for safety monitoring and alert systems.

Valve Response Performance Characteristics

Response time is a critical safety parameter in emergency energy isolation scenarios. The DM2® Series C provides exceptionally fast pressure response across all sizes:

Basic Size 2 Performance

• Filling 0-30 psi: <200ms
• Filling 0-60 psi: <300ms
• Exhausting 90-60 psi: <150ms
• Exhausting 90-30 psi: <250ms

Basic Size 4 Performance

• Filling 0-30 psi: <250ms
• Filling 0-80 psi: <450ms
• Exhausting 90-60 psi: <180ms
• Exhausting 90-9 psi: <350ms

Basic Size 8 Performance

• Filling 0-30 psi: <300ms
• Filling 0-80 psi: <550ms
• Exhausting 90-60 psi: <200ms
• Exhausting 90-9 psi: <400ms

Basic Size 12 Performance

• Filling 0-30 psi: <350ms
• Filling 0-80 psi: <600ms
• Exhausting 90-60 psi: <220ms
• Exhausting 90-9 psi: <450ms

Basic Size 30 Performance

• Filling 0-30 psi: <400ms
• Filling 0-80 psi: <700ms
• Exhausting 90-60 psi: <250ms
• Exhausting 90-9 psi: <500ms

These response times ensure rapid energy isolation when safety systems detect hazardous conditions, protecting workers from injury.

Model Configuration & Ordering Information

The DM2® Series C uses a comprehensive model numbering system enabling precise specification:

Model Number Format Example: DM2CDB20A21005

Configuration Parameters:

Available Port Configurations:

• B20 (Size 2): 1/4" In, 1/4" Out, 3/4" Exhaust
• B21 (Size 2): 3/8" In, 3/8" Out, 3/4" Exhaust
• B42 (Size 4): 1/2" In, 1/2" Out, 1" Exhaust
• A54 (Size 8): 3/4" In, 3/4" Out, 1" Exhaust
• A55 (Size 8): 1" In, 1" Out, 1" Exhaust
• A66 (Size 12): 1" In, 1" Out, 1-1/2" Exhaust
• A88 (Size 30): 1-1/2" In, 2" Out, 2-1/2" Exhaust

Accessories & Integration Solutions

Status Indicator Options

Pressure monitoring devices provide real-time safety system feedback:

Connector & Wiring Solutions

ROSS provides comprehensive electrical integration options:

• DIN EN 175301-803 Form A Connectors: Standard industrial connector with flying leads or fixed coupling options
• M12 Connectors: Modern compact 5-pin connector supporting lighted and non-lighted variants
• Prewired Cable Kits: 2-meter to 50-meter lengths with factory-assembled connector configurations
• J-Box Junction Solutions: 10-pin mini junction boxes for multi-valve installations with centralized control
• Custom Wiring Kits: 24VDC, 120VAC, and 230VAC voltage-specific configurations

Noise Reduction Solutions

High-flow silencers are available for all valve sizes, reducing exhaust noise by 17-25 dB while maintaining full flow capacity:

Port Pressure Monitoring

Redundant pressure switch assemblies and energy release verification sensors enable comprehensive circuit monitoring for enhanced safety verification:

• Dual Redundant Verification: RC026-13 with dual electrical contacts for fail-safe monitoring
• Energy Release Verification: 586A86 pressure switch for downstream pressure confirmation

Safe Air Entry System Assemblies

Complete safe entry system kits combine DM2® Series C safe exhaust valves with manual lockout L-O-X® devices, FRL combinations, and air preparation modules, providing integrated energy isolation solutions for comprehensive machine safety.

Dimensional Specifications & CAD Resources

The DM2® Series C is designed for flexible mounting with industry-standard base configurations:

Size 2 Dimensions:

• Height: 10.32" (262.2mm)
• Width: 4.74" (120.4mm)
• Depth: 7.90" (200.8mm)
• Weight: 5.3 lbs (2.4 kg)

Size 4 Dimensions:

• Height: 9.97" (253.2mm)
• Width: 4.34" (110.2mm)
• Depth: 12.0" (304.8mm)
• Weight: 5.9 lbs (2.6 kg)

Size 8 Dimensions:

• Height: 11.90" (302.3mm)
• Width: 5.41" (137.4mm)
• Depth: 6.23" (158.2mm)
• Weight: 8.4 lbs (3.7 kg)

Size 12 Dimensions:

• Height: 13.71" (348.2mm)
• Width: 6.74" (117.2mm)
• Depth: 9.85" (250.2mm)
• Weight: 15.3 lbs (3.7 kg)

Size 30 Dimensions:

• Height: 16.87" (428.5mm)
• Width: 9.85" (250.2mm)
• Depth: 11.82" (300.3mm)
• Weight: 34.7 lbs (15.1 kg)

Downloadable CAD Models: Complete 3D CAD models in standard formats are available for each valve size and configuration, enabling seamless integration into system designs and virtual commissioning environments.

Installation, Maintenance & Service Guidelines

Pre-Installation Requirements

Before servicing or installing any pneumatic component:

1. Ensure all energy sources are turned off and the entire pneumatic system is shut down and exhausted
2. Lock out all power sources per OSHA 1910.147 and EN 1037 standards
3. Read all installation and operation instructions thoroughly
4. Verify proper training and experience with pneumatic equipment among personnel

Filtration & Lubrication Specifications

Optimal performance requires proper air preparation:

• Recommended Filtration: 5-micron filter rating for normal applications
• Lubrication Compatibility: Mineral oils per DIN 51519, viscosity classes ISO 32 or lighter
• Lubrication Additives: Avoid phosphate-type additives that damage polyurethane components
• Operating Flexibility: Valves function with or without in-line lubrication due to PTFE backup rings

Exhaust Port Restrictions

Proper exhaust silencer selection is critical:

• Silencer Flow Capacity: Must equal or exceed valve exhaust capacity
• Clog Resistance: Use high-flow, clog-resistant silencers to prevent back-pressure buildup
• Flow Performance: Do not restrict exhaust flow, as back-pressure adversely affects valve operation

Minimum Operation Requirements

The DM2® Series C requires monthly operation to maintain functional safety verification. Valves used less frequently should be exercised monthly to ensure proper operation and dynamic monitoring function.

Functional Safety System Integration

For mechanical power presses and hazardous machinery applications:

1. Incorporate a control system providing continuous monitoring of the safe exhaust valve
2. Implement monitoring that inhibits further machinery operation if a valve failure is detected
3. Note: L-O-X® and L-O-X® with EEZ-ON® devices are defined as energy isolation devices, NOT emergency stop devices

Warranty & Product Support

Standard ROSS Warranty: All DM2® Series C valves are warranted for one (1) year from purchase date, free from defects in material and workmanship. The ROSS Group's warranty obligation is limited to repair, replacement, or refund of purchase price for products determined to be defective.

Warranty Exclusions: Warranties become void if products experience misuse, misapplication, improper maintenance, modification, or tampering. All warranty claims require freight prepaid return to ROSS.

Extended Service & Support: The DM2® Series C benefits from ROSS's global support network with representatives in North America, Europe, Asia, and Pacific regions. Local distributors provide technical assistance, replacement parts availability, and emergency support.

Global Distribution & Technical Support

ROSS Global Locations:

North America

• ROSS Controls (USA): +1-248-764-1800
• ROSS Canada: +1-416-251-7677
• ROSS Brasil: +55-11-4335-2200

Europe

• ROSS Europa (Germany): +49 (0)6103-7597-100
• ROSS France: +33-(0)1-49-45-65-65
• ROSS UK: +44 (0)1254 872277

Asia & Pacific

• ROSS Controls India: +91-44-2624-9040
• ROSS Controls China: +86-21-6915-7961
• ROSS Asia (Japan): +81-42-778-7251

Distributor Network: With 100+ authorized distributors worldwide, ROSS ensures local availability of products, replacement parts, and technical support. Our extensive distribution network guarantees responsive service regardless of location.

Industry Applications & Real-World Use Cases

The DM2® Series C safe exhaust valves are essential components in critical safety systems across demanding manufacturing environments:

Automotive Manufacturing In automotive assembly plants and press operations, DM2® Series C valves protect workers during tool changeovers and maintenance operations. The rapid energy isolation and integrated monitoring ensure compliance with ISO 13849-1 functional safety requirements and machine safety directives.

Metal Forming & Fabrication Large stamping presses, shears, and forming equipment utilize DM2® Series C valves to safely isolate pneumatic energy during die changes and maintenance. The robust poppet design withstands contamination from metal chips and coolant mist inherent in metalworking environments.

Packaging & Converting High-speed filling, sealing, and labeling machines incorporate DM2® Series C valves as part of lockout/tagout safety systems. The compact size and flexible mounting enable seamless integration into space-constrained machine designs while providing uncompromised safety.

Glass Manufacturing Float glass and container glass production lines use DM2® Series C valves to control pneumatic drive mechanisms safely. The valve's ability to function with or without lubrication suits the harsh, contamination-prone glass production environment.

Press Control Systems Mechanical power press safety systems require the redundant control, dynamic monitoring, and integrated failure detection that only DM2® Series C valves provide. These valves are essential components in press control systems meeting Category 4, PL e requirements per ISO 13849-1 standards.

Machine Tool Automation CNC machining centers and multi-spindle automatic machines use DM2® Series C valves for safe pneumatic energy control during automatic tool changers, spindle release systems, and work-holding mechanisms.

Download Complete Technical Documentation

The DM2® Series C catalog includes comprehensive technical information essential for system design, installation, and maintenance:

Included Documentation:

• Complete functional specifications and dimensional drawings
• Electrical schematics and connector pinouts
• Operating condition parameters and pressure/temperature ratings
• Valve response performance curves for all sizes
• Model numbering system and configuration guide
• Accessory specifications and integration options
• Installation and maintenance guidelines
• Safety certifications and compliance documentation

CAD & Engineering Resources:

• 3D CAD models (STEP, IGES, and DWG formats)
• 2D dimensional drawings with mounting hole patterns
• Electrical connection diagrams
• Piping schematic examples
• Performance characteristic curves
• SISTEMA simulation library files

Customize Your Valve Configuration

Use the ROSS/FLEX customization program to configure the exact DM2® Series C valve for your application. Select from multiple size options (2, 4, 8, 12, 30), port configurations, voltage ratings (24VDC, 110/120VAC, 230VAC), connector styles (flying leads or M12), and status indicator types.

Configure Your DM2® Series C Valve

Request Application Engineering Support

ROSS controls provides comprehensive application engineering support for integrating DM2® Series C safe exhaust valves into complex safety systems. Our application engineers work with your team to ensure optimal valve selection, system integration, safety compliance, and commissioning.

Schedule a Consultation with ROSS Application Engineers

Find Your Local ROSS Distributor

Need quick delivery or local technical support? ROSS's global distributor network ensures responsive service and rapid parts availability worldwide.

FAQ Section

Q: What is the difference between DM2® Series C and DM2® Series D valves? A: DM2® Series C valves are designed for safe exhaust (dump) applications in general industrial machinery. DM2® Series D valves are specifically engineered for controlling clutch/brake mechanisms on mechanical power presses, which have different functional requirements. The Series D features press-specific design characteristics for press control applications.

Q: Can the DM2® Series C be reset automatically after a lockout event? A: No. The DM2® Series C's integrated dynamic memory requires an explicit reset signal via the dedicated reset solenoid or remote reset valve. The valve cannot be reset by simply removing and reapplying supply pressure. This design prevents accidental reactivation and ensures conscious manual intervention before restoring normal operation.

Q: What is the residual outlet pressure after DM2® Series C lockout? A: Less than 1% of inlet supply pressure. This extremely low residual pressure ensures maximum worker safety by virtually eliminating the risk of unexpected energy release that could cause injury.

Q: Do DM2® Series C valves require in-line lubrication? A: No. The PTFE backup piston rings enable operation with or without in-line lubrication. This flexibility allows simplified system design without sacrificing performance or reliability.

Q: What is the typical service life of DM2® Series C valves? A: The Mean Time to Failure (MTTF) is 301.9 years with 662,400 hours of operation, indicating exceptionally long service life. The B10D rating of 20,000,000 cycles means the valve will function reliably through 20 million complete operating cycles before reaching a 10% failure probability.

Q: Are DM2® Series C valves suitable for use in pharmaceutical or food processing applications? A: The DM2® Series C can be used in these applications with proper air preparation and system design. ROSS provides complete traceability documentation, material certifications, and validation support for regulated industry compliance.

Q: What is Category 4, PL e certification? A: Category 4 and Performance Level e (PL e) are the highest safety integrity classifications per ISO 13849-1:2015. These ratings indicate redundant control architecture with integrated diagnostics enabling safe system operation even in the event of single-component failures.

Technical Terms & Definitions

• PLe (Performance Level e): The highest performance level per ISO 13849-1:2015, indicating capability to detect and manage failures while maintaining safe operation
• SIL 3 (Safety Integrity Level 3): Per IEC 61061:2001, indicating suitability for systems managing hazardous energy that could cause serious injury or death
• Poppet Design: Direct-acting poppet element providing quick response and high flow capacity with minimal moving parts
• Dynamic Monitoring: Continuous internal monitoring during each valve cycle detecting asymmetrical operation indicating failure conditions
• Residual Pressure: Pressure remaining downstream of the valve after lockout; minimized for maximum worker safety
• Redundant Control: Two independent control channels ensuring operation continues if one channel experiences a failure
• Asynchronous Movement: Unequal response time between dual valve elements indicating a failure condition triggering safe lockout

Related ROSS Products & Solutions

• L-O-X® Lockout/Isolation Valves: Manual energy isolation devices for pneumatic systems
• L-O-X® with EEZ-ON®: Enhanced ease-of-operation lockout valves for frequent access requirements
• Air Preparation Systems: FRL combinations providing filtered, regulated, lubricated compressed air
• Pressure Switches & Sensors: Monitoring devices for safety system feedback and diagnostics
• Safe Entry System Assemblies: Complete kits combining safe exhaust valves with lockout devices

Compliance & Standards References

• ISO 13849-1:2015: Safety of machinery - Safety-related parts of control systems
• IEC 61061:2001: Functional safety of electrical/electronic/programmable electronic safety systems
• EN 954-1: Safety of machinery - Safety-related control systems (superseded by ISO 13849-1)
• OSHA 1910.147: Lockout/Tagout requirements for machinery energy isolation
• EN 1037: Safety of machinery - Safeguarding - Protective stops
• ISO 9001: Quality management system certification
• DIN 40050 / IEC 60529: Electrical enclosure IP rating classifications
• VDE 0580: German electrical equipment safety standards