W65 Series ISO 5599-2 Valves – Installation & Operating Instructions

Overview

The ROSS Controls® W65 Series is a precision spool-and-sleeve pneumatic valve designed for mounting on bases with an ISO 5599/II interface. As a product of ROSS Controls – a fluid power company founded in 1921 with over 100 years of engineering expertise – the W65 Series delivers high performance in demanding industrial directional control applications. Available in ISO Sizes 1, 2, and 3, these valves accommodate a broad range of flow requirements from compact automation circuits to high-volume process control systems.

The spool-and-sleeve design of the W65 Series provides smooth, precise control of airflow with low hysteresis and excellent repeatability. The stainless steel spool paired with bar-stock aluminum valve body ensures dimensional stability and long service life even under continuous cycling conditions. Solenoid pilot variants are available in single and double configurations, and pressure-controlled versions support remote pilot actuation.

Whether integrating into new equipment or replacing valves in an existing ISO 5599-2 system, the W65 Series offers a drop-in compatible solution backed by ROSS's comprehensive service kit program. Contact ROSS Controls at 1-800-GET-ROSS or visit www.rosscontrols.com for distributor support and technical documentation.

Key Features

Precision Spool-and-Sleeve Design

The W65 Series employs a matched stainless steel spool-and-sleeve assembly that provides precise flow control with minimal internal leakage. Each spool and sleeve is a matched set; care must be taken not to reverse the spool position during reassembly. The assembly requires only a single drop of Anderol 735 (or equivalent) on each spool land for lubrication. Dry assembly is preferred for non-lubricated applications.

ISO 5599/II Interface for Easy Integration

W65 Series valves conform to the ISO 5599/II interface, enabling direct mounting on ISO Size 1, 2, and 3 sub-bases and manifolds from multiple manufacturers. The standardized port layout (Ports 1, 2, 3, 4, 5 with pilot ports 12 and 14) ensures interchangeability without base modifications, reducing installation time and simplifying future maintenance.

Single and Double Solenoid Pilot Options

The W65 Series is available with single solenoid pilot, double solenoid pilot, or pressure pilot actuation. Single solenoid models spring-return to one position upon de-energization, while double solenoid models maintain their last commanded position. Pressure pilot models use remote air signals for actuation, making them suitable for hazardous or explosive environments where electrical actuation is not permitted.

ROSS Silencer Compatibility for Noise Reduction

Exhaust ports (3 and 5) on the W65 Series can be fitted with ROSS silencers, which reduce exhaust impact noise by as much as 25 dB. Silencers for the W65 Series are available from ROSS and authorized distributors. Restriction of exhaust ports should be minimized to avoid adverse effects on valve performance.

Technical Specifications

The following specifications are from the official ROSS Controls W65 Series ISO 5599-2 Valves Installation Instructions (Doc ID 39):

Construction Design: Spool and sleeve
Mounting Type: Base (ISO 5599/II interface)
Valve Body Material: Bar stock aluminum
Spool Material: Stainless steel
Seal Material: Buna-N
Flow Media: Filtered air
Solenoids: Rated for continuous duty
Pressure Controlled Valves – Ambient/Media Temperature: 40° to 175°F (4° to 80°C); contact ROSS for other ranges
ISO Size 1 Operating Pressure: 30 to 150 psig (2 to 10 bar)
ISO Size 2 & 3 Operating Pressure: 15 to 150 psig (1 to 10 bar)
All sizes also available up to 232 psig (16 bar)
Pilot Supply: Minimum 30 psig (2 bar); pilot pressure must be equal to or greater than inlet pressure
Optional features: Indicator light, manual override

For spool and sleeve reassembly: place one drop of Anderol 735 (or equivalent) on each spool land, insert spool into sleeve, and rotate several times to distribute lubricant evenly. Before inserting the spool-and-sleeve assembly into the valve body, lightly lubricate O-rings with MobilGrease 28. Do not use Anderol on O-rings as it causes deterioration.

Applications

Multi-Actuator Machine Control

W65 Series valves are well suited for machine control applications requiring ISO 5599-2 compatible directional control across multiple actuator circuits. Their availability in Sizes 1, 2, and 3 allows engineers to select the optimal flow capacity for each axis, and the ISO interface enables manifold mounting to consolidate valve banks and reduce installation complexity in multi-actuator systems.

Process and Packaging Automation

In packaging, food and beverage, and process automation, W65 Series valves provide reliable directional control for pneumatic actuators operating in high-cycle environments. The precision spool-and-sleeve construction ensures consistent performance over millions of cycles, and ROSS service kits enable cost-effective maintenance without full valve replacement.

Safety and Compliance Standards

W65 Series valves conform to ISO 5599/II interface standards. Solenoid electrical enclosures meet applicable IEC standards for industrial equipment. All installation and maintenance must be performed by personnel trained and experienced in pneumatic equipment. The electrical supply must match the voltage and frequency ratings printed on the valve.

Before beginning any installation or service, disconnect the electrical supply, shut off the air supply, and depressurize all lines connected to the valve. Use a 5-micron rated air filter in the inlet line and drain the filter bowl regularly. For automatic drainage, install a filter with an automatic drain.

Installation and Setup Guide

Air Line Preparation

Before installing the W65 Series valve in a new or existing system, blow all air lines clean of contaminants. Install a 5-micron rated filter in the inlet line close to the valve. An inadequate or restricted air supply to Port 1 (inlet) will adversely affect valve performance.

Pilot Supply Configuration

For solenoid-controlled models using internal pilot: ensure port 14 in the base is plugged. For external pilot supply (required when inlet pressure is below minimum pilot pressure, or for non-air service), connect the external supply to port 14. For pressure-controlled models with single remote control, connect to port 14; for double remote control, connect to both ports 12 and 14.

Pipe and Fitting Installation

Install pipe in valve ports by engaging one turn, applying pipe thread sealant to male threads (not tape), then tightening. This prevents sealant from entering valve internals. For solenoid pilot models, the electrical connection is made via the plug-in connector on the valve; ensure supply voltage matches rated values before connecting.

Why Choose ROSS Controls

ROSS Controls has over a century of leadership in fluid power solutions. The W65 Series is part of a comprehensive portfolio of ISO-compatible pneumatic valves supported by full service kits, global distributor networks, and direct technical engineering support. ROSS Controls products are used in automotive, aerospace, food processing, and general manufacturing worldwide.

Contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com for product selection, service kits, and distributor locations.

Download This Document

The official ROSS Controls W65 Series ISO 5599-2 Valves Installation Instructions (Doc ID 39) can be downloaded from the ROSS Controls document library.

PDF Download URL: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/39/ROSS_W65_Series_ISO_5599-2_Valves_Installation_Instructions.pdf

Frequently Asked Questions

Q: What is the difference between the W64 and W65 Series valves?

A: The W64 Series uses a poppet construction and ISO 5599-1 interface, while the W65 Series uses a spool-and-sleeve construction and ISO 5599-2 (ISO 5599/II) interface. Spool-and-sleeve valves provide different flow characteristics and are preferred in applications requiring smooth modulation.

Q: What ISO sizes are available in the W65 Series?

A: W65 Series valves are available in ISO Sizes 1, 2, and 3. Size 1 operates at 30 to 150 psig (2 to 10 bar). Sizes 2 and 3 operate at 15 to 150 psig (1 to 10 bar). All sizes are also available up to 232 psig (16 bar) for higher-pressure applications.

Q: What is the minimum pilot supply pressure for W65 Series valves?

A: The minimum pilot supply pressure is 30 psig (2 bar). The pilot supply pressure must be equal to or greater than the inlet pressure at all times. For external pilot applications, connect the pilot supply to port 14 in the base.

Q: How should the spool and sleeve be lubricated during reassembly?

A: Apply one drop of Anderol 735 (or equivalent) on each spool land. Insert the spool into the sleeve and rotate several times to distribute the lubricant. For non-lubricated applications, dry assembly is preferable to avoid lubricant residue. Before inserting into the valve body, lightly lubricate O-rings with MobilGrease 28 – do not use Anderol on O-rings.

Q: Can W65 Series valves be used with fluid media other than air?

A: Non-air service applications require an external pilot supply for solenoid valves, connected to port 14 in the base. For media other than filtered air, consult ROSS Technical Services to verify compatibility with valve materials and seals.

Q: What temperature range do W65 Series pressure-controlled valves support?

A: Pressure-controlled W65 Series valves have an ambient/media temperature range of 40° to 175°F (4° to 80°C). For applications outside this range, contact ROSS Controls for guidance on special temperature configurations.

Q: Are solenoid indicators available for the W65 Series?

A: Yes. Indicator lights and manual overrides are optional features available on W65 Series solenoid pilot valves. These options provide visual confirmation of solenoid status and allow manual actuation during testing and commissioning.

Q: How do I prevent pipe sealant from contaminating the valve?

A: When installing pipe, engage the pipe one turn into the port, then apply pipe thread sealant to the male threads only. Do not use pipe thread tape (PTFE tape) as it can shred and contaminate the spool-and-sleeve assembly. Tighten the pipe after applying sealant.

Q: What solvent should be used to clean the W65 Series valve?

A: Use a solvent that dries without leaving a residue. This is especially important for the spool-and-sleeve assembly. Do not use chlorinated solvents (they damage seals) or abrasive materials (they permanently damage metal parts).

Q: Where can I find service kits and replacement parts for the W65 Series?

A: Service kits are available from ROSS Controls and authorized distributors. Contact ROSS at 1-800-GET-ROSS or find your local distributor at www.rosscontrols.com. Reference Doc ID 39 for specific kit part numbers.