Critical Safety Features and Technology

Electro-Pneumatic (E-P) Internal Monitoring System

The SERPAR® 35 Series with electro-pneumatic monitoring provides the highest level of safety assurance for press control applications. The E-P monitor continuously verifies the proper operation of both valve elements throughout each machine cycle. This sophisticated monitoring system detects:

• Valve element failure detection: Identifies when either redundant valve fails to shift or return to the safe position
• Crossflow verification: Ensures air passes through both valve elements simultaneously during actuation
• Real-time fault identification: Instantly recognizes pneumatic or mechanical malfunctions
• Automatic lockout functionality: Immediately inhibits further machine operation upon detecting any fault condition
• Dedicated reset requirement: Prevents unintended restart after fault detection, requiring deliberate operator intervention

The electro-pneumatic monitoring system eliminates the need for external monitoring circuitry, significantly reducing installation complexity and potential failure points in the safety circuit. The built-in monitoring device checks for proper operation of each valve element on every single cycle, providing unprecedented reliability in critical safety applications.

Dual Poppet Valve Construction

ROSS 35 Series valves feature proven dual poppet design that delivers exceptional performance in demanding industrial environments:

• Dirt-tolerant operation: Poppet design resists contamination that would compromise other valve types
• Wear-compensating technology: Maintains consistent response times throughout the valve's operational life
• High flow capacity: Optimized flow paths ensure rapid actuation and de-actuation of clutch/brake mechanisms
• Quick response times: Critical for emergency stop situations and cycle-accurate press control
• PTFE backup piston rings: Enable reliable operation with or without in-line air lubrication

The poppet construction provides inherent fail-safe characteristics, defaulting to the de-energized (exhaust) position upon loss of electrical power or pneumatic supply, ensuring worker safety under all failure modes.

Applications and Industry Use Cases

Mechanical Press Clutch and Brake Control

The primary application for ROSS 35 Series SERPAR® valves is control of pneumatically-actuated clutch and brake mechanisms on mechanical stamping presses. These valves provide:

• Redundant control reliability: Dual valve elements ensure safety even if one component fails
• Dynamic monitoring: Verifies proper valve function during every press stroke
• Memory function: Maintains lockout condition until deliberately reset
• OSHA compliance: Meets requirements of 29 CFR 1910.217 for mechanical power press safety
• ANSI B11.1 conformance: Satisfies industry standards for press brake and press safety systems

The valves control air supply to friction clutches and brakes, enabling precise press stroke initiation and immediate stopping capability. The monitoring system ensures both valve elements function correctly before allowing hazardous press motion.

Alternative Lockout/Tagout Systems

ROSS 35 Series valves serve as critical components in alternative lockout systems for machine energy isolation during maintenance and servicing:

• Category 3 and Category 4 safety circuits: Achieve required safety integrity levels per ISO 13849-1
• Lockout inhibit capability: Prevents machine restart during maintenance operations
• Visual status indication: Provides clear confirmation of energy isolation state
• Integrated exhaust: Rapidly dumps downstream air pressure for zero-energy state
• Compliance with ANSI/ASSE Z244.1: Meets control of hazardous energy standards

These applications protect maintenance personnel during jam clearance, die changes, and routine servicing by ensuring pneumatic energy cannot be inadvertently restored.

Air Cylinder Press Load-Holding Systems

For pneumatic and hydraulic cylinder presses, ROSS 35 Series valves provide essential safety functions:

• Load-holding circuit control: Maintains cylinder position under load
• Anti-tie-down protection: Prevents bypassing of two-hand control systems
• Emergency exhaust capability: Enables rapid pressure release in hazardous conditions
• Redundant position verification: Monitors cylinder position via valve state

The internally monitored design ensures the safety circuit maintains integrity throughout the press cycle, preventing unexpected ram descent that could cause severe injury.

Technical Specifications and Available Configurations

Port Sizes and Flow Capacities

The ROSS 35 Series catalog details valves available in multiple basic sizes to accommodate varied application requirements:

• Basic Size 4: Port sizes from 3/8" to 3/4" for lower flow applications
• Basic Size 8: Port sizes from 1/2" to 1-1/4" for medium flow requirements
• Basic Size 12: Port sizes from 3/4" to 1-1/2" for higher flow demands
• Basic Size 30: Larger configurations for high-volume applications

Flow coefficients (Cv values) range from 3.5 for smaller valve configurations to 43 for larger exhaust ports, enabling proper sizing for clutch/brake actuation times and downstream system volumes. The catalog includes detailed flow data and response time calculations to assist engineers in proper valve selection.

Electrical Specifications

SERPAR® 35 Series valves accommodate standard industrial electrical requirements:

• Standard voltages: 24 VDC, 110-120 VAC 50/60 Hz
• Pilot solenoid configuration: Two solenoids rated for continuous duty
• Power consumption: 87 VA inrush, 30 VA holding (AC); 14 watts (DC)
• Reset solenoid: Rated for intermittent duty with same voltage options
• Electrical connections: Terminal strip or EN 175301-803 Form A connectors
• Enclosure rating: IP65 per IEC 60529 for industrial environment protection

The catalog specifies exact electrical requirements for each valve model, enabling accurate electrical panel design and power supply sizing.

Pneumatic Operating Parameters

Operating specifications ensure reliable performance across typical industrial compressed air systems:

• Pressure range: 30 to 125 psig (2 to 8.5 bar) inlet pressure
• Reset pressure (L-G models): 60 psig (4 bar) minimum for pneumatic reset
• Flow media: Filtered compressed air, 5-micron filtration recommended
• Temperature range: 40°F to 175°F (4°C to 80°C) media temperature
• Ambient temperature: 40°F to 120°F (4°C to 50°C)

These specifications ensure valves operate reliably within standard plant air system parameters without requiring special conditioning or preparation.

Monitoring System Options

Electro-Pneumatic (E-P) Monitor

The E-P monitoring system represents the most advanced internal monitoring technology:

• Built-in electronic monitoring: No external monitoring circuitry required
• Continuous cycle verification: Checks valve function on every actuation
• Electrical fault output: Provides signal to machine control system
• DPDT switch integration: Double-pole, double-throw switch for redundant signaling
• Solenoid reset capability: Enables remote reset from operator station

E-P models support both single input signal (internally jumpered solenoids) and dual input signal (independently wired solenoids) configurations, accommodating different control architectures.

Pneumatic (L-G) Monitor

The L-G (Large-to-Ground) pneumatic monitor provides reliable monitoring through pneumatic logic:

• Pneumatic signal verification: Monitors air pressure differential across valve elements
• Mechanical spool detection: Uses pressure-operated spool to detect faults
• Air signal reset: Pneumatic reset port for remote or local reset
• No electrical components: Ideal for applications requiring intrinsically safe design
• Simple integration: Works with existing pneumatic control systems

L-G monitors offer proven reliability in harsh environments where electronic monitoring might be compromised by electromagnetic interference or extreme conditions.

Dual Monitoring Option

For applications requiring redundant monitoring per CSA Z142, ROSS offers dual-monitored valves combining both E-P and L-G systems:

• Redundant dissimilar monitors: Two completely independent monitoring systems
• Independent signal sources: Separate monitoring verification for maximum safety integrity
• CSA Z142 compliance: Meets Canadian Standards Association requirements
• Enhanced diagnostic coverage: Achieves near-100% fault detection capability

Installation and Mounting Configurations

In-Line Mounting System

The 35 Series features in-line mounting with removable flanges:

• Threaded port connections: NPT or BSPP threads for standard piping
• Removable flanges: Simplifies installation and valve replacement
• Piping flange kits: Available separately for custom installations
• Mounting orientation: Any orientation acceptable, vertical preferred with solenoids on top
• Compact footprint: Space-efficient design for crowded control panels

The catalog includes dimensional drawings showing mounting hole patterns, port locations, and clearance requirements for proper installation planning.

Built-In Silencer Technology

ROSS 35 Series valves include integrated high-flow, non-clogging silencers:

• Noise reduction: Minimizes exhaust noise during valve de-actuation
• Clog-resistant design: Large exhaust passages prevent blockage from debris
• No back pressure: Maintains rapid exhaust times critical for press safety
• Maintenance-free operation: No cleaning or servicing required
• Remote exhaust option: Threaded flange available for duct exhaust applications

The built-in silencer eliminates the need for external mufflers, reducing installation costs and potential failure points.

Safety Standards Compliance and Certifications

OSHA 1910.217 Compliance

ROSS 35 Series SERPAR® valves enable compliance with Occupational Safety and Health Administration requirements for mechanical power presses:

• Control reliability: Meets OSHA definitions for control reliable operation
• Redundancy requirements: Provides dual valve element configuration
• Monitoring capability: Detects and responds to single valve element failures
• Inhibit function: Prevents press operation after fault detection

The catalog includes application notes explaining how to implement compliant press control systems using SERPAR® valves in conjunction with proper control architecture.

ANSI B11.1 Conformance

The valves support compliance with American National Standards Institute B11.1 standards for mechanical power presses:

• Category 4 safety systems: Achieves highest safety category per ANSI B11.19
• Single fault tolerance: Continues safe operation after single component failure
• Fault detection capability: Identifies failures before next demand on safety function
• Exclusion of faults: Design prevents accumulation of undetected faults

ISO 13849-1 Category 4, PLe Achievement

When properly integrated into safety circuits, ROSS 35 Series valves contribute to achieving:

• Performance Level e: Highest safety performance level for industrial machinery
• Category 4 architecture: Redundancy with fault detection and exclusion
• Diagnostic coverage: Up to 99% fault detection capability
• Mean Time to Dangerous Failure: Extended MTTFD through proven design

The catalog references SISTEMA library files available for download to facilitate safety circuit design and validation calculations.

Model Selection and Ordering Information

The catalog provides comprehensive model numbering explanations:

Model Number Format: 3573 - A - 4 - 1 - 4 - 1 - W

• 3573: Series designation for SERPAR® with E-P monitor
• A: Flange type (A = with flange, D = BSPP threads)
• 4: Basic size (4, 5, 6, 7, 8 corresponding to port sizes)
• 1: Input configuration (1 = single input, 3 = dual input)
• 4: Override option (4 = with override, 6 = without override)
• 1: Reset type (1 = solenoid reset, 2 = air signal reset)
• W: Voltage code (W = 24 VDC, Z = 110-120 VAC)

This systematic model numbering enables precise specification of required valve configuration for any application.

Installation Instructions and Wiring Diagrams

The catalog includes detailed installation guidance:

• Pneumatic schematic symbols: Standard symbols for system design documentation
• Piping recommendations: Proper line sizing and installation practices
• Electrical wiring diagrams: Single input and dual input configurations
• Terminal strip connections: Pin assignments and signal descriptions
• Pressure switch connections: External monitoring integration when required

Step-by-step installation instructions ensure proper valve commissioning and integration into existing machine control systems.

Maintenance and Troubleshooting

While SERPAR® valves require minimal maintenance, the catalog provides:

• Preventive maintenance schedules: Recommended inspection intervals
• Troubleshooting flowcharts: Systematic fault diagnosis procedures
• Common failure modes: Recognition and resolution of typical issues
• Spare parts identification: Component replacement part numbers
• Service life expectations: Expected operational life under various conditions

Why Download This Catalog

This comprehensive technical resource is essential for:

Safety Managers: Understanding how SERPAR® valves enable OSHA and ANSI compliance for press safety systems

Maintenance Engineers: Reference for troubleshooting, parts ordering, and system upgrades

Control Engineers: Detailed wiring diagrams and integration specifications for safety circuit design

Machine Builders: Complete specifications for incorporating proven safety technology into new press designs

Plant Managers: ROI information on reducing press-related injuries and associated costs

Procurement Specialists: Model numbering system and technical specifications for accurate ordering

Additional Resources Included in Catalog

The ROSS 35 Series catalog provides supplementary information including:

• Application examples: Real-world implementations with system schematics
• Response time calculations: Formulas and examples for determining actuation times
• Sizing guidelines: Methodology for selecting appropriate valve size and flow capacity
• Accessory information: Available options including piping flanges, remote reset switches
• Cross-reference tables: Comparison with competitive valve offerings
• Technical support contact information: Direct access to ROSS application engineers

Download Your Copy Today

Access the complete ROSS 35 Series SERPAR® Press Control Clutch/Brake Monitored Double Valves catalog to:

✓ Ensure your mechanical press control systems meet current safety standards
✓ Properly specify valves for new installations or retrofits
✓ Train maintenance personnel on SERPAR® valve operation and troubleshooting
✓ Reference technical specifications during safety system design
✓ Evaluate upgrade options for aging press control systems

The PDF catalog is immediately accessible for download and includes printable pages for shop floor reference and engineering file documentation.