21 & 27 Series Poppet Valves and Adaptors Safety Manual

Overview

ROSS Controls, founded in 1921 with over 100 years of leadership in fluid power, publishes this safety manual for ROSS Poppet Valves (pneumatic) for Line Mounting — Series 27 and 21 — with optional adaptors (Series "Headline"). This document covers 2/2, 3/2, and 4/2-way valves (normally closed, normally open) and adaptors including the Timed Sequence adaptor (in/out), "PB" adaptor, and "Q" adaptor. The manual was developed in accordance with IEC 61508 and is required reading for engineers integrating ROSS Headline series poppet valves into SIL-rated safety functions.

The ROSS Europa GmbH safety manual (Document ID D-RE-04, Version 1.2) provides the necessary functional safety data for use in safety system design, including systematic capability assessment, SIL claim limits, proof test intervals, and failure rate data. It is intended for use by qualified functional safety engineers performing safety integrity level (SIL) assessments for machine safety applications.

This manual covers the complete Headline series product range for line mounting: valve body configurations (2/2 NC, 2/2 NO, 3/2 NC, 3/2 NO, 4/2), plus optional adaptors that add timing, pulse, or logic functions. For application-specific guidance, contact ROSS Europa GmbH or ROSS Controls at 1-800-GET-ROSS or www.rosscontrols.com.

Key Features

SIL Safety Manual Covering Headline Series 21 and 27

The Headline Series 21 and 27 poppet valves are available with optional adaptors that extend functional capabilities. The PB adaptor provides a pulse or bistable function. The Q adaptor enables quick-exhaust or flow control functions. The timed sequence adaptor introduces in or out delays. The safety manual documents the SIL claim limits and systematic capability for each valve and adaptor combination, enabling engineers to correctly attribute safety integrity credit for each configuration.

Multiple Valve Function Configurations

The Headline series covers 2/2-way, 3/2-way, and 4/2-way directional control valve functions in both normally closed (NC) and normally open (NO) configurations. Valve actuation is available in electrical (solenoid) and pneumatic options. Inline mounting with G1/4 through G1-1/2 connection threads accommodates a wide range of line sizes. Dimensional data for all configurations is provided in the technical documentation.

Bilingual German/English Documentation

The safety manual is published bilingually in German and English, reflecting ROSS Europa GmbH's commitment to serving European and global markets. The document is current as of Version 1.2 (January 2015) and was reviewed and released by ROSS Europa GmbH. The document number is D-RE-04.

Technical Specifications

Product Series: ROSS Poppet Valves (pneumatic) for Line Mounting, Series 27 and 21
Trade Name: Headline Series
Valve Functions: 2/2, 3/2, 4/2-way directional control valves (NC and NO)
Actuation: Electrical (solenoid) and pneumatic
Connection Threads: G1/4 through G1 1/2 (metric), various ranges per configuration
Available Adaptors: Timed Sequence (in/out), PB adaptor, Q adaptor
Manufacturer: ROSS Europa GmbH, Robert-Bosch-Str. 2, D-63225 Langen (Hessen), Germany
Safety Standard: IEC 61508
Document Version: V1.2 (2014/11)
Document ID: D-RE-04
Published: Bilingual German/English

Applications

SIL-Rated Safety System Integration

Engineers designing machine safety systems to SIL 1, SIL 2, or SIL 3 requirements need detailed functional safety data for each component in the safety function. This safety manual provides the necessary data for ROSS Headline Series 21 and 27 valves and their adaptors, enabling correct SIL assessment and documentation required for CE marking and functional safety audits under IEC 62061 and EN ISO 13849-1.

European Machine Directive Compliance

Machinery sold in the European Economic Area must comply with the Machinery Directive 2006/42/EC and supporting harmonized standards. For pneumatic safety functions, ROSS Headline series poppet valves with the documented SIL data from this manual provide the functional safety evidence required for CE conformity assessment, particularly for safety functions involving pneumatic energy isolation, direction control, or cylinder stop.

Safety and Compliance Standards

This safety manual must be read and understood before integrating Headline Series 21/27 poppet valves into safety-rated applications. The document defines scope of application, systematic capability limits, and applicable third-party documentation. Use the safety data provided to calculate SIL capability for the complete safety function. Contact ROSS Europa GmbH for SIL certificates and declarations of conformity.

Installation and Setup Guide

Safety System Integration Steps

Step 1: Read this complete safety manual before specifying or installing valves in SIL-rated safety functions.
Step 2: Identify the required valve function configuration (2/2, 3/2, or 4/2-way NC or NO).
Step 3: Determine whether optional adaptors (PB, Q, timed sequence) are required for the safety function.
Step 4: Verify that the selected configuration's SIL claim limit meets the required SIL for the application.
Step 5: Use failure rate data from the manual in safety function PFHD calculations.
Step 6: Follow installation instructions in the respective product-specific installation documentation.
Step 7: Perform proof tests at the interval specified in the safety manual to maintain SIL compliance over service life.
Step 8: Document all safety-relevant installation and maintenance activities for the machine technical file.

Why Choose ROSS Controls

ROSS Controls, founded in 1921 with over 100 years of leadership in fluid power, provides complete functional safety documentation for all ROSS safety-rated products, enabling machine builders and safety engineers to achieve required SIL or PL levels with confidence. ROSS's global network includes safety engineering specialists available through 1-800-GET-ROSS or www.rosscontrols.com.

Download This Document

PDF download: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/377/ROSS_Headline_SIL_SafetyManual_DE_EN_2020-02-24_.pdf

Frequently Asked Questions

Q: What series of valves does this safety manual cover?

A: The ROSS Headline Series — poppet valves for line mounting, Series 21 and 27 — in 2/2, 3/2, and 4/2-way configurations, with optional PB, Q, and timed sequence adaptors.

Q: What safety standard is this manual based on?

A: IEC 61508, the international standard for functional safety of electrical, electronic, and programmable electronic systems.

Q: Who is the publisher of this safety manual?

A: ROSS Europa GmbH, Robert-Bosch-Str. 2, D-63225 Langen (Hessen), Germany. Document ID: D-RE-04, Version 1.2.

Q: What languages is the manual published in?

A: Bilingual German and English.

Q: What adaptors are covered in this safety manual?

A: Timed Sequence adaptor (in/out delay), PB adaptor, and Q adaptor.

Q: What valve actuation methods are covered?

A: Both electrical (solenoid) actuation and pneumatic actuation.

Q: Where can I get SIL certificates and declarations of conformity?

A: Contact ROSS Europa GmbH or visit www.rosscontrols.com for available certificates and declarations.

Q: What connection thread sizes are available?

A: G1/4 through G1 1/2 metric threads, with dimensions varying by valve configuration — see technical documentation for complete dimensional data.