77 Series CrossMirror® Solenoid Pilot Controlled Double Valves Installation Instructions

Overview

ROSS Controls, founded in 1921 with over 100 years of leadership in fluid power, offers the 77 Series CrossMirror® Solenoid Pilot Controlled Double Valves as 4-way, control-reliable double valves for machine safety applications requiring dual-channel electrical control. This valve version is actuated by two independent solenoid pilots that must be energized simultaneously to shift the valve to the actuated state. If either solenoid fails or the solenoids are not energized simultaneously, the valve defaults to the safe state.

The solenoid-piloted 77 Series uses precision stainless steel spools as main valve elements and is designed to offer added safety to pneumatically controlled machines. The valve achieves Category 4, Performance Level e (ISO 13849-1) functional safety. Port 2 is normally open (pressurized when de-actuated); Port 4 is normally closed (pressurized only when both solenoids are simultaneously energized). A pressure switch status indicator is available in models ending in "1" to signal out-of-step valve element movement to external safety controls.

IMPORTANT: This valve is not designed for controlling clutch/brake mechanisms on mechanical power presses. Contact ROSS at 1-800-GET-ROSS or rosscontrols.com.

Key Features

Dual Solenoid Simultaneous Actuation Requirement

Both pilot solenoids must be energized simultaneously for the 77 Series to shift Port 4 to the pressurized state. If only one solenoid is energized, or if the two solenoids are not energized within the allowable discordance window, the valve defaults with Port 2 pressurized and Port 4 exhausted. When both solenoids are subsequently de-energized, the valve returns to normal de-actuated state and is ready to resume normal operation as soon as both solenoids have been de-energized.

Precision Stainless Steel Spool and Sleeve Construction

The stainless steel spool and sleeve construction provides long service life and consistent valve response. The spool and sleeve assembly is serviceable: use Anderol 735 (or equivalent) lubricant — one drop per spool land, rotate for even distribution. Each spool and sleeve is a matched set; do not reverse the spool position in the sleeve. For non-lubricated applications, dry assembly is preferred. Use the listed compatible lubricants for O-ring lubrication; do not use Anderol on O-rings.

Pressure Switch Status Monitoring

The optional pressure switch status indicator (available in models with number ending in "1") detects when the main valve elements did not move together, closing electrical contacts on out-of-step movement. Terminals 1 and 4 are connected when pressure is present and the valve is ready-to-run. Terminals 1 and 2 are connected when abnormal operation has occurred or inlet pressure is removed. Pin 2 is normally closed; Pin 4 is normally open.

Technical Specifications

Construction Design: Double Spool and Sleeve, precision stainless steel
Mounting Type: Base mounted
Ambient Temperature: 40° to 122°F (4° to 50°C)
Media Temperature: 40° to 175°F (4° to 80°C)
Flow Media: Filtered air
Inlet Pressure: See Valve Specifications page 3 of source document
Port 2: Normally open (pressurized when de-actuated)
Port 4: Normally closed (pressurized when both solenoids energized)
Pressure Switch: Terminals 1&4 = ready-to-run; Terminals 1&2 = fault or no pressure
Pressure Switch Pins: Pin 1 Common; Pin 2 Normally Closed; Pin 4 Normally Open; Pin G not used
Electrical Connection: Plug-in connectors
Functional Safety Data: Category 4 PL e; B10D: 20,000,000; PFHD: 7.71×10⁻⁹
Certifications: CE Marked, BG

Applications

Dual-Channel Safety PLC / Safety Relay Integration

The solenoid-piloted 77 Series is the preferred double valve for integration with dual-channel safety relay or safety PLC outputs. Each output channel drives one pilot solenoid. The valve's internal monitoring verifies simultaneous solenoid actuation and de-actuation, providing the Category 4 PL e redundancy verification without requiring additional external monitoring for the valve itself.

Two-Hand Electrical Control Stations

In electrical two-hand control stations, two push buttons each control one channel of a safety relay, which in turn drives both solenoids of the 77 Series valve. The anti-tie-down logic of the safety relay combined with the valve's internal monitoring provides a complete two-hand control solution. The pressure switch feedback confirms valve ready-to-run status to the safety relay for pre-cycle validation.

Safety and Compliance Standards

Pneumatic equipment must be installed and maintained by trained personnel. Electrical supply must match solenoid voltage and hertz ratings. Do not restrict Exhaust Ports 3 and 5. Clean valve spool and sleeve with a solvent that dries without residue — no chlorinated solvents or abrasives. Keep electrical switch/relay contacts in good condition. Before service, shut off electrical power, shut off air supply, and exhaust the system.

Installation and Setup Guide

Installation Steps

Step 1: Blow air lines clean; install 5-micron rated filter upstream.
Step 2: Mount valve onto base; connect Inlet Port 1.
Step 3: Connect Ports 2 and 4 to actuator circuits with adequate line sizes, free of crimps.
Step 4: Do not restrict Exhaust Ports 3 and 5.
Step 5: Connect both pilot solenoids to the dual-channel safety relay or safety PLC output.
Step 6: Verify electrical supply matches voltage/hertz rating on pilot housing.
Step 7: Connect pressure switch output to external monitoring if required.
Step 8: Test simultaneous solenoid energization — verify Port 4 pressurizes only when both solenoids actuated.
Step 9: Test de-actuation — verify Port 4 exhausts and Port 2 pressurizes when solenoids are de-energized.
Step 10: Verify pressure switch status indicator responds correctly.

Why Choose ROSS Controls

ROSS Controls, founded in 1921 with over 100 years of leadership in fluid power, has been the global leader in CrossMirror® double valve technology for over 50 years. The 77 Series solenoid-piloted valve provides Cat. 4 PL e / SIL 3 performance with CE and BG certification. Contact ROSS at 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/97/ROSS_77_Series_CrossMirror_Double_Valves_Solenoid_Pilot_Controlled_Installation_Instructions_SS149.pdf

Frequently Asked Questions

Q: What happens if only one solenoid is energized?

A: The valve remains in the de-actuated state with Port 2 pressurized and Port 4 exhausted. Port 4 is only pressurized when both solenoids are simultaneously energized.

Q: What is the pressure switch pin assignment?

A: Pin 1: Common. Pin 2: Normally Closed (connected to Pin 1 when abnormal or pressure removed). Pin 4: Normally Open (connected to Pin 1 when pressure present / ready-to-run). Pin G: Not used.

Q: What lubricant should be used for spool and sleeve reassembly?

A: Anderol 735 or equivalent — one drop per spool land, rotate to distribute evenly. For O-rings: use listed compatible lubricants only, not Anderol.

Q: What is the functional safety rating?

A: Category 4, Performance Level e (ISO 13849-1); B10D: 20,000,000; PFHD: 7.71×10⁻⁹.

Q: Can the spool be reversed in the sleeve?

A: No. Each spool and sleeve is a matched set. Do not reverse the spool position in the sleeve.

Q: Can this valve be used for press clutch/brake control?

A: No. The 77 Series is not designed for controlling clutch/brake mechanisms on mechanical power presses.

Q: What does "de-energize to return to ready" mean?

A: After a malfunction where valve elements moved out of step, the valve resumes ready state as soon as both solenoids have been de-energized — no separate reset signal is required for the basic 77 Series solenoid valve.

Q: What cleaning solvents are approved?

A: Use a solvent that dries without leaving a residue. Do not use chlorinated solvents or abrasive materials that damage seals or metal parts.