This detailed technical resource includes complete specifications, configuration options, dimensional drawings, performance data, and application guidelines for implementing safe air entry systems that comply with international safety standards including ISO 13849-1, ANSI B11.19, and EN ISO 13849. Whether you're designing new machinery, retrofitting existing equipment, or upgrading pneumatic safety systems to meet current compliance requirements, this catalog serves as your essential reference guide.

MDC Series Safe Exhaust Valve Technologies

The MDC Series Safe Exhaust Valves represent ROSS Controls' newest advancement in single poppet safety valve design, specifically engineered for applications requiring up to Category 2, Performance Level c safety ratings. These valves fulfill the critical safety function of shutting off pneumatic energy supply while simultaneously exhausting downstream pneumatic pressure to create a safe machine state.

MDC1 Series - Category 1, PL c

The MDC1 Series valve provides fundamental safety exhaust functionality for Category 1 applications without solid-state pressure sensor feedback. This economical solution delivers:

• 3/2 normally closed function with single poppet design
• External monitoring capability through control system integration
• Safety Category 1, PL c rating suitable for lower-risk machine applications
• SIL 1 (Safety Integrity Level 1) functional safety certification
• Cost-effective implementation for budget-conscious safety upgrades

The MDC1 Series is ideal for applications where basic pneumatic safety control is required, including small pneumatic presses, valve operators, automated assembly stations, and pick-and-place systems.

MDC2 Series - Category 2, PL c

The MDC2 Series advances safety performance by incorporating a solid-state pressure sensor that provides real-time feedback to external safety controls, enabling Category 2, PL c ratings. Key differentiators include:

• Integrated pressure sensor feedback for enhanced diagnostic capability
• Diagnostic coverage between 60% and 90% per ISO 13849-1 requirements
• External monitoring with sensor validation on each actuation and de-actuation cycle
• "Fail-to-safe" functionality ensured when poppet returns to start position
• Enhanced reliability for medium-risk pneumatic applications

The MDC2 Series serves applications requiring validated safety performance, including larger cylinder presses, automated material handling systems, robotic workcells, and packaging machinery with guarded access points.

EEZ-ON® Soft-Start Function

A distinguishing feature of the MDC Series is the integrated EEZ-ON® (Soft-Start) function, which provides controlled pressure build-up during system energization. Upon solenoid activation, outlet pressure increases gradually until reaching approximately 50% of inlet pressure, then opens fully to complete system pressurization at full rate.

Benefits of Soft-Start Technology:

• Prevents equipment damage from sudden pressure surges
• Reduces mechanical shock to cylinders, actuators, and tooling
• Extends component life by minimizing wear on seals and bearings
• Protects operators from unexpected rapid machine movement
• Eliminates water hammer effects in pneumatic distribution systems
• Improves process control for sensitive manufacturing operations

System Components and Configurations

The Safe Air Entry Assembly integrates multiple critical safety and air preparation components into a single, factory-tested, ready-to-install system. This pre-engineered approach reduces installation time, eliminates field assembly errors, and ensures optimal component compatibility.

Manual Lockout L-O-X® Valve

The foundation of every Safe Air Entry Assembly is ROSS's proven Lockout L-O-X® Valve, available in two configurations:

Classic Lockout L-O-X® Valve:

• Large, ergonomic push/pull handle for positive direct manual operation
• Lockable only in the OFF position with padlock hasp
• Full-size exhaust port (equal to or larger than supply) for rapid pressure release
• Fluorocarbon slipper seals for easy operation even after extended inactivity
• Integrated sensing port for pressure verification or visual indicator options
• Meets OSHA 1910.147 Lockout/Tagout requirements
• Complies with EN ISO 14118 and ANSI Z244.1 energy isolation standards

Modular Lockout L-O-X® Valve:

• Compact modular design for space-constrained installations
• Identical safety performance to Classic series
• Direct mounting to MD Series air preparation components
• Streamlined footprint for panel-mounted applications
• Threaded or modular port connections

Air Preparation (FRL) Components

Professional-grade air preparation is essential for reliable pneumatic safety system operation. The catalog details multiple FRL (Filter-Regulator-Lubricator) configurations using ROSS's MD Series components:

MD3™ Series - Compact FRL Systems:

• Suitable for 1/4" and 3/8" port size applications
• Integrated filter/regulator combinations for space savings
• Optional lubricator for applications requiring lubrication
• Metal bowl construction for durability in harsh environments

MD4™ Series - Standard FRL Systems:

• Designed for 1/2" through 3/4" port applications
• Available in side-by-side or integrated filter/regulator configurations
• Pressure gauge options (analog or digital transducer)
• Automatic drain or manual drain bowl options

High-Capacity Series - Large Flow Applications:

• Engineered for 1" through 1-1/2" port sizes
• High-flow capacity for large cylinder applications
• Heavy-duty construction for continuous-duty operations
• Modular expansion capabilities

FRL Component Features:

• 40-micron filtration standard (10-micron available)
• Pressure regulation from 5-125 PSI (adjustable)
• Metal bowls for superior impact resistance and visibility
• Differential pressure gauges to monitor filter condition
• Modular connection systems for simplified assembly

MDC Series Safe Exhaust Valve Integration

The MDC1 or MDC2 Series valve mounts directly to the air preparation assembly outlet, providing the final safety control element before pneumatic distribution to machinery.

Mounting Configurations:

• Inline/Modular mounting for 1/2" body size (3/8" through 3/4" port options)
• Inline mounting for 1" body size (3/4" through 1-1/4" port options)
• Base mounting available for valve replacement accessibility
• Plate mounting for panel or enclosure installation

Optional Components and Accessories

The catalog includes extensive information on system customization options:

• Extra port blocks (1/4", 3/8", 1/2") for branch connections
• Upstream or downstream port placement for flexible piping
• Silencers (canister or high-flow) for noise reduction
• Drip leg assemblies to remove contaminants before air entry
• Mounting plates and brackets for various installation scenarios
• Pressure indicators (visual or gauge-based monitoring)

Safety Performance Levels and Certifications

Understanding safety performance ratings is critical for proper safety system design. The catalog provides detailed guidance on achieving required safety categories and performance levels.

ISO 13849-1 Safety Categories

Category 1 (MDC1 Series):

• Single-channel safety function with well-tried components
• Suitable for low-risk applications (PL c achievable)
• Fault detection through functional testing during normal operation
• Mean Time To Dangerous Failure (MTTFd): Low to Medium
• Basic safety integrity without continuous diagnostic monitoring

Category 2 (MDC2 Series):

• Single-channel with test equipment (pressure sensor feedback)
• Diagnostic coverage (DC) between 60% and 90%
• Periodic testing by control system validates safety function
• Suitable for medium-risk applications (PL c achievable)
• Enhanced reliability through validated sensor monitoring

Performance Level (PL) Ratings

Both MDC1 and MDC2 Series achieve Performance Level c (PL c), representing:

• Probability of dangerous failure: 10⁻⁶ to 10⁻⁵ per hour
• Average risk reduction factor of 100-1,000
• Appropriate for machinery with Medium risk levels per ISO 12100
• Compatible with safety-rated PLCs and control systems

Safety Integrity Level (SIL) Ratings

• SIL 1 certification for both MDC1 and MDC2 Series
• Suitable for integration into SIL 1 or SIL 2 safety functions
• Documented failure rate data for PFDavg calculations
• Compatible with IEC 61508 and IEC 62061 functional safety standards

Global Certifications and Standards Compliance

The catalog details compliance with international safety authorities:

• DGUV Certification (Pending) - German statutory accident insurance
• CE Marking - European Machinery Directive 2006/42/EC compliance
• UKCA Certification - UK Conformity Assessed marking
• CSA/UL Certification (Pending) - North American safety standards
• EAC Declaration - Eurasian Conformity for Russian/CIS markets
• ANSI B11.19 - Performance requirements for safeguarding
• ISO 4414 - Pneumatic fluid power systems and components
• OSHA 1910.147 - Control of hazardous energy (Lockout/Tagout)

Applications and Industries

The Safe Air Entry Assembly with MDC Series valves serves diverse industrial applications requiring reliable pneumatic safety control.

Manufacturing and Assembly

• Pneumatic cylinder presses (stamping, forming, punching operations)
• Automated assembly lines with robotic pick-and-place systems
• Part clamping and fixturing in machining centers
• Automated fastening systems (riveting, screwing, clinching)
• Material transfer systems with pneumatic conveying
• Valve automation for process control applications

Packaging Industry

• Form-fill-seal machines with pneumatic actuation
• Case erectors and packers requiring safe access during maintenance
• Labeling machines with cylinder-operated applicators
• Palletizers and depalletizers with multiple pneumatic zones
• Carton forming and sealing equipment with guarded access points
• Shrink wrap and stretch wrap systems with safety interlocks

Automotive Manufacturing

• Welding fixtures and positioners with pneumatic clamping
• Paint booth door operators requiring lockout capability
• Assembly tooling changeover systems with quick-release fixtures
• Tire mounting and balancing equipment with cylinder-operated mechanisms
• Brake testing stations with pneumatic actuation
• Engine assembly lines with multiple pneumatic work stations

Food and Beverage Processing

• Filling machines with pneumatic valve control
• Capping and sealing equipment requiring frequent sanitization access
• Sorting and diverting systems with cylinder-operated gates
• Conveyor systems with pneumatic transfers and indexing
• Bottle rinsing and washing machines with cylinder actuation
• Carton erecting and forming in packaging lines

Glass Manufacturing

• IS (Individual Section) machines requiring zone isolation
• Blow molding equipment with multiple pneumatic circuits
• Transfer mechanisms in container production
• Quality inspection systems with pneumatic reject gates
• Palletizing equipment for finished container handling

Steel and Metals Industry

• Roll forming lines with pneumatic clamping and positioning
• Coil processing equipment requiring energy isolation for maintenance
• Metal stamping presses with pneumatic clutch/brake control
• Shearing and cutting machines with cylinder-operated blades
• Material handling systems in harsh mill environments

Technical Specifications and Features

Valve Performance Specifications

Port Size Options:

• 1/2" Body Size: 3/8", 1/2", 3/4" inlet/outlet ports
• 1" Body Size: 3/4", 1", 1-1/4" inlet/outlet ports
• Exhaust Port: 1" (1/2" body) or larger for rapid pressure release

Flow Characteristics:

• Cv ratings optimized for each port size configuration
• High flow capacity for large cylinder applications
• Minimal pressure drop in open state for energy efficiency

Pressure Ratings:

• Operating pressure: Up to 120 PSI (8.3 bar)
• Proof pressure: 1.5x operating pressure
• Burst pressure: 4x operating pressure minimum

Electrical Specifications (MDC2 with sensor):

• Voltage: 24 VDC standard
• Power consumption: 15 watts maximum
• Electrical connection: M12, DIN EN 175301-803 Form C options
• Sensor output: Solid-state pressure sensor feedback
• Protection rating: IP65 or IP67 depending on connector selection

Construction and Materials

Poppet Valve Design:

• Single poppet construction for simplicity and reliability
• Dirt-tolerant design compensates for wear over service life
• PTFE backup piston rings enable operation with or without lubrication
• Corrosion-resistant materials for extended service in harsh environments
• Wear-compensating geometry maintains performance specifications

Housing and Body:

• Anodized aluminum body for lightweight, corrosion-resistant construction
• Stainless steel fasteners for durability
• Fluorocarbon seals for chemical resistance and temperature stability
• Impact-resistant design suitable for industrial environments

Exhaust Performance

• High-flow, clog-resistant silencer included with most configurations
• Canister silencer available for reduced exhaust noise levels
• Remote exhaust options for contaminated environments
• Rapid exhaust capability for fast machine stop times
• Threaded exhaust port for custom exhaust routing

Configuration Options and Customization

The catalog provides detailed model number configurators enabling precise system specification for your application requirements.

Configuration Variables

Valve Series Selection:

• MDC1 (Category 1, PL c) without pressure sensor
• MDC2 (Category 2, PL c) with solid-state pressure sensor

Soft-Start Function:

• Included (recommended for most applications)
• Not included (for applications requiring immediate full pressure)

Monitoring Type:

• External monitoring (via control system integration)

Electrical Specifications:

• Voltage: 24 VDC, 110/120 VAC options
• Connector: M12, DIN EN 175301-803 Form A or Form C

Thread Type:

• NPT (National Pipe Thread) - North American standard
• G (BSPP - British Standard Pipe Parallel) - International standard

Gauge Options:

• Analog gauge (traditional dial indicator)
• Digital transducer (electronic pressure monitoring)
• No gauge (when separate monitoring used)

Lockout Valve Type:

• Classic L-O-X® (standard push/pull handle)
• Modular L-O-X® (space-saving modular design)
• Not included (when separate lockout used)

Lockout Location:

• Before FRL (upstream of air preparation)
• After FRL (downstream of air preparation)

FRL Configuration:

• MD3™, MD4™, or High-Capacity series
• Side-by-side filter/regulator or integrated unit
• With or without lubricator

Additional Options:

• Extra port blocks (1/4", 3/8", 1/2") upstream or downstream
• Plate mounting for panel installation
• Drip leg for moisture removal
• Custom configurations via ROSS/FLEX® engineering

Installation and Integration Benefits

Pre-Engineered System Advantages

Factory Testing and Quality Assurance:

• Complete assembly tested before shipment
• All connections leak-tested and verified
• Electrical continuity and sensor validation performed
• Quality documentation provided with each unit

Reduced Installation Time:

• Up to 60% faster installation compared to field-assembled components
• Pre-wired electrical connections minimize field wiring
• Modular mounting eliminates complex piping fabrication
• Mounting plates included for straightforward mechanical installation

Improved Reliability:

• Factory-optimized component spacing prevents thermal interference
• Professional-grade fittings and connections eliminate leak points
• Verified component compatibility ensures proper operation
• Reduced field assembly errors through pre-configuration

Simplified Maintenance:

• Single-point lockout simplifies machine de-energization procedures
• Modular construction enables component replacement without full system disassembly
• Standard component interfaces support inventory management
• Diagnostic capabilities (MDC2) accelerate troubleshooting

Safety System Integration

Control System Compatibility:

• Compatible with safety-rated PLCs (Rockwell GuardLogix, Siemens Failsafe, etc.)
• Sensor outputs interface with standard safety input modules
• Valve status feedback enables comprehensive machine monitoring
• SISTEMA Library files available for safety calculation support

Compliance Documentation:

• Technical files support CE marking and machinery risk assessment
• Installation instructions include safety function validation procedures
• Wiring diagrams simplify electrical design and documentation
• Certification documents facilitate regulatory compliance

ROSS/FLEX® Custom Solutions

For applications requiring unique configurations beyond standard catalog offerings, ROSS offers ROSS/FLEX® application engineering services:

• Direct collaboration with ROSS engineering team
• Custom packaging of standard internal components
• Elimination of life-cycle testing through proven component reuse
• Rapid development (days rather than weeks or months)
• Cost-effective solutions tailored to specific requirements

SISTEMA Library Support

All Safe Air Entry Assemblies with MDC Series valves include access to SISTEMA Library files for download from the ROSS Controls website. SISTEMA (Safety Integrity Software Tool for the Evaluation of Machine Applications) is the industry-standard software tool for calculating Performance Levels according to ISO 13849-1.

SISTEMA Library Benefits:

• Pre-validated component safety data
• Simplified safety calculation process
• Reduced engineering time for safety function design
• Support for compliance documentation and regulatory approval
• Integration with complete machine safety architecture

Why Choose ROSS Controls Safe Air Entry Assemblies?

100+ Years of Valve Innovation

Since 1921, ROSS Controls has been a global leader in fluid power safety solutions, pioneering technologies including:

• First double valve technology (1953)
• Revolutionary L-O-X® lockout valve
• Industry-leading DM2® dynamic monitoring technology
• Comprehensive pneumatic, hydraulic, and electrical safety solutions

Global Support Network

• Worldwide technical support available in multiple languages
• Regional distribution for rapid product availability
• Application engineering assistance for complex safety systems
• Training programs including Certified Functional Safety Expert (CFSE) courses

Quality and Reliability

• ISO 9001:2015 certified manufacturing
• Rigorous testing protocols for every product
• Long-term component availability and support
• Proven performance in millions of installations worldwide

Download Your Free Catalog Today

This comprehensive catalog provides everything you need to specify, configure, and implement Safe Air Entry Assemblies with MDC Series double valves for your pneumatic safety applications. Whether you're upgrading existing equipment to meet current safety standards, designing new machinery, or seeking cost-effective alternatives to higher-category safety valves, this catalog is your essential resource.

Inside You'll Find:

• Complete dimensional drawings and technical specifications
• Model number configurators for precise ordering
• Installation instructions and mounting guidelines
• Electrical wiring diagrams and sensor integration details
• Application examples across multiple industries
• Compliance documentation and certification information
• Troubleshooting guides and maintenance recommendations

Contact ROSS Controls

For technical support, application assistance, or custom ROSS/FLEX® solutions, contact our expert team:

Phone: 800-438-7677 (U.S.) | 248-764-1800 (International)
Email: sales@rosscontrols.com
Website: www.rosscontrols.com

Headquarters:
ROSS Controls
Ferndale, Michigan, USA
Global Leader in Fluid Power Safety Since 1921