W60 Series ISO 5599-1 Directional Control Valves Installation Instructions

Overview

The ROSS Controls W60 Series ISO 5599-1 Directional Control Valves are stainless steel spool and sleeve pneumatic directional valves built to the highest quality standards and designed to the ISO 5599-1 interface. The ISO 5599-1 standard defines port sizes, mounting holes, and valve interface dimensions, enabling W60 Series valves to be interchanged with other ISO 5599-1-compliant valve bodies and manifolds.

The W60 Series uses a spool and sleeve construction with stainless steel spool and bar stock aluminum valve body. Buna-N seals provide compatibility with standard compressed air systems. The valve operates across a pressure range from vacuum to 150 psig (10 bar) and supports both internal and external pilot supply configurations.

The W60 is available in multiple configurations including 5/2 (5-port, 2-position) and other functions, with solenoid pilot, spring return, and other actuation options. Temperature range is 40° to 120°F (4° to 50°C) ambient and 40° to 175°F (4° to 80°C) media. For other temperature ranges, consult ROSS. ROSS Controls was founded in 1921 and has over 100 years of fluid power expertise. Contact ROSS at 1-800-GET-ROSS or visit rosscontrols.com.

Key Features

ISO 5599-1 Interface Compliance

The W60 Series is designed to the ISO 5599-1 standard, which specifies port sizes, mounting dimensions, and interface geometry for interchangeable pneumatic directional control valves. ISO 5599-1 compliance means the W60 can be mounted on ISO 5599-1-compatible manifolds and bases from ROSS and other manufacturers, simplifying system design and valve replacement.

Stainless Steel Spool and Sleeve

The stainless steel spool and sleeve construction provides excellent corrosion resistance and long service life compared to aluminum spool designs. Stainless steel is particularly valuable in environments with corrosive atmospheres, elevated humidity, or where compatibility with specific process fluids is required. The bar stock aluminum body provides lightweight strength for the overall valve assembly.

Internal and External Pilot Supply

The W60 supports both internal pilot supply (pilot air drawn from Port 1 inlet) and external pilot supply (dedicated pilot supply line connected to the pilot port). External pilot supply is useful when the main line pressure is too low to reliably operate the pilot section, or when pilot supply must be maintained when the main supply is shut off.

Broad Pressure Range from Vacuum to 150 psig

The W60 Series operates from vacuum to 150 psig (10 bar), accommodating both vacuum handling applications and standard industrial compressed air supply. This versatility makes the W60 suitable for a wide range of automation and material handling applications.

Technical Specifications

Specifications from W60 Series installation instructions:

Construction Design: Spool and Sleeve
Valve Body Material: Bar Stock Aluminum
Spool Material: Stainless Steel
Seals: Buna-N
Mounting Type: Base (ISO 5599-1)
Flow Media: Filtered compressed air
Ambient Temperature: 40° to 120°F (4° to 50°C)
Media Temperature: 40° to 175°F (4° to 80°C)
Operating Pressure: Vacuum to 150 psig (10 bar)
Pilot Supply: Internal or External
Pilot Supply External Range: Consult valve specifications for required pressures
Standard Voltages: 24 volts DC; 110–120 volts AC, 50/60 Hz
Solenoid: Rated for continuous duty (pilot-operated models)
Electrical Connections: Plug-in connector per solenoid label
Noise Reduction: ROSS 55 Series silencers recommended for exhaust ports (up to 25 dB reduction)

Applications

Pneumatic Actuator and Cylinder Control on ISO Manifolds

The W60 Series is ideal for manifold-mounted pneumatic valve islands where ISO 5599-1 compliance is required for interchangeability. Manufacturing automation lines, material handling systems, and assembly equipment that use ISO 5599-1 manifolds can deploy the W60 as the directional control valve for cylinders, rotary actuators, grippers, and other pneumatic devices.

Process and Factory Automation

The stainless steel spool construction makes the W60 particularly suitable for process industry, food and beverage, and chemical plant automation applications where corrosion resistance, long service life, and reliable pneumatic control are priorities. The ISO 5599-1 interface ensures compatibility with standard automation platforms.

Safety and Compliance Standards

ISO 5599-1 — Pneumatic directional control valve interface standard
ROSS recommended: 5-micron-rated inlet air filter
ROSS recommended: ROSS 55 Series silencers for exhaust ports 3 and 5
Compatible lubricants: petroleum base oils, ISO 32 or lighter; avoid phosphate-additive oils

Installation and Setup Guide

Air Line Preparation

Before installing the valve, blow all air lines clean. Install a 5-micron-rated air filter in the inlet line. Clean air supply is essential for spool valve performance and service life.

Port Connections

Port 1 (Inlet): Supply line must be adequately sized and free of crimps and sharp bends. Ports 2 and 4 (Outlets): Locate the valve close to the actuated mechanism. Lines must be adequately sized and free of restrictions. Ports 3 and 5 (Exhausts): Use ROSS 55 Series silencers to reduce exhaust noise by as much as 25 dB with minimal back pressure. Do not restrict exhaust flow.

Solenoid Electrical Connection

The voltage and hertz ratings are printed on the solenoid side. Connect the electrical supply via the plug-in connector whose prongs correspond to the sketch on the solenoid pilot. If power is supplied by a transformer, it must handle inrush current without significant voltage drop.

External Pilot Supply (If Required)

If the valve is configured for external pilot supply, connect a dedicated pilot supply line to the pilot supply port. The pilot supply pressure requirements are provided in the valve specifications section of the installation instructions. Ensure pilot pressure is maintained within the specified range.

Why Choose ROSS Controls

ROSS Controls has been manufacturing premium pneumatic valve products since 1921. The W60 Series combines ISO 5599-1 compliance with ROSS's signature quality in stainless steel spool design. Contact ROSS at 1-800-GET-ROSS or visit rosscontrols.com for technical documentation and distributor information.

Download This Document

The official W60 Series ISO 5599-1 Valves installation instructions are available as a free PDF download from ROSS Controls.

PDF Download URL: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/16/ROSS_W60_Series_ISO_5599-1_Valves_Installation_Instruction.pdf

Frequently Asked Questions

Q: What is ISO 5599-1?

A: ISO 5599-1 is an international standard that defines the interface dimensions, port sizes, and mounting geometry for pneumatic directional control valves. Compliance ensures that valves from different manufacturers with the same ISO 5599-1 size designation can be used on the same manifold bases, simplifying system design and enabling valve replacement without manifold changes.

Q: What construction material is used for the W60 spool?

A: The W60 spool is stainless steel, providing excellent corrosion resistance and long service life. The valve body is bar stock aluminum with Buna-N seals.

Q: What is the operating pressure range?

A: Vacuum to 150 psig (10 bar).

Q: Does the W60 support external pilot supply?

A: Yes. The W60 supports both internal and external pilot supply configurations. External pilot supply is useful when main line pressure is too low to reliably pilot the valve, or when independent pilot pressure control is required.

Q: What temperature range is supported?

A: Ambient: 40° to 120°F (4° to 50°C). Media: 40° to 175°F (4° to 80°C). For other temperature ranges, consult ROSS Controls.

Q: What standard voltages are available?

A: 24 volts DC and 110–120 volts AC at 50/60 Hz for solenoid pilot models.

Q: How do I reduce exhaust noise on the W60?

A: Install ROSS 55 Series silencers in the exhaust ports (Ports 3 and 5). ROSS silencers reduce exhaust impact noise by up to 25 dB with minimal back pressure.

Q: What lubricants are compatible with the W60?

A: Petroleum-based oils with oxidation inhibitors, aniline point 180–220°F (82–104°C), ISO 32 or lighter viscosity. Avoid oils with phosphate additives (e.g., zinc dithiophosphate) and diester oils, which can damage valve seals.

Q: Can I use the W60 in corrosive environments?

A: The stainless steel spool provides good corrosion resistance. For highly corrosive environments, consult ROSS Controls regarding material compatibility and alternative seal materials.

Q: Where can I find technical documentation for the W60?

A: Download the installation instructions PDF from the URL above. Additional technical documentation is available at rosscontrols.com, or call 1-800-GET-ROSS.