DM2® Series D Control Reliable Double Valves Installation Instructions — Press Clutch/Brake Control
Overview
The ROSS Controls DM2® Series D is a premium-quality control-reliable electropneumatic double valve with dynamic monitoring and inherent lockout capability, specifically designed for Category 4 press clutch/brake control applications on mechanical power presses. This is the dedicated ROSS press valve — the DM2® Series D provides the specific flow, exhaust, and lockout characteristics required to safely control air clutch/brake mechanisms in mechanical power press operations.
The DM2® Series D is designed for base mounting and is available in Basic Sizes 2, 4, 8, 12, and 30 to accommodate the full range of press sizes from small, high-speed presses to large, slow-speed heavy-duty presses. The crossflow passage design, anti-tie-down reset feature, and inherent lockout with memory make the DM2® Series D the benchmark pneumatic safety valve for press clutch/brake control worldwide.
ROSS Controls, founded in 1921, invented the SERPAR® concept and continues to advance press safety valve technology. The DM2® Series D is protected by U.S. Patents 6840258 and 6840259 and worldwide patents. Installation instructions document SS293 covers Basic Sizes 2 through 30.
Key Features
Specifically Engineered for Press Clutch/Brake Control
The DM2® Series D differs from the DM2® Series C in its specific flow, exhaust, and lockout characteristics tailored for mechanical power press applications. It meets OSHA requirements for press clutch/brake control and is designed for the duty cycles, pressure requirements, and safety functions demanded by mechanical power press operations.
Inherent Lockout with Memory and Anti-Tie-Down Reset
The DM2® Series D provides inherent lockout with memory — once a fault is detected (asynchronous valve element movement), the valve locks out and cannot resume operation until an intentional reset signal is applied. The anti-tie-down feature requires both main solenoids to be de-energized before reset can occur, preventing unintended press stroke initiation upon reset. Minimum 200 ms delay between reset completion and solenoid re-energization is required.
Crossflow Architecture — Self-Contained Monitoring
The DM2® Series D is completely self-contained and does not require an external monitoring system. Crossflow passages between both main valve elements ensure both must fully shift before Port 2 can be pressurized. The pilot supply monitoring through inlet poppet positions detects any element timing discordance within approximately 125 milliseconds.
Technical Specifications
- Safety Category: Category 4 per ISO 13849-1
- Application: Press clutch/brake control on mechanical power presses
- Construction Design: Dual poppet with crossflow passages
- Basic Sizes: BG 2, BG 4, BG 8, BG 12, BG 30
- Reset Type: Inherent lockout with memory — intentional reset required
- Anti-Tie-Down: Both main solenoids must be de-energized during reset
- Discordance Detection Time: Approximately 125 milliseconds
- Reset Duration: Momentary; 200 ms minimum recommended
- Post-Reset Delay: 200 ms minimum before re-energizing main solenoids
- Reset Method: Solenoid reset (on-valve) or air reset (RESET port with external 3/2 NC valve)
- Filter Recommendation: 5-micron rated air filter at inlet
- Exhaust: Factory-equipped ROSS silencer (up to 25 dB noise reduction)
- Status Indicator: Optional — pressure switch with 4 contacts
- Electrical Connection: Plug-in connectors
- Standard Voltages: 24 VDC; 110–120 VAC, 50/60 Hz
- Monitoring: Self-contained — no external monitoring required
- Patents: U.S. 6840258 / 6840259; worldwide patents pending
Applications
Mechanical Power Press Clutch/Brake Control
The DM2® Series D is the primary ROSS valve for mechanical power press clutch/brake control applications. It is suitable for all types of mechanical power presses: single-stroke, partial-revolution, full-revolution, and continuous stroke configurations. The valve is compatible with both single-point and two-point mechanical presses and satisfies OSHA 29 CFR 1910.217 requirements for press safety controls.
Other Category 4 Press and Hazardous Machine Applications
Beyond mechanical power presses, the DM2® Series D is used in other Category 4 applications on hazardous machines where the specific flow and exhaust characteristics of a press-style double valve are required. This includes forging presses, injection molding machines, and other cyclically operated hazardous machinery.
Safety and Compliance Standards
- OSHA 29 CFR 1910.217 — Mechanical power presses (press clutch/brake control)
- ISO 13849-1 — Category 4 compliance
- ANSI B11.1 — Safety requirements for mechanical power presses
- CSA Z142 — Power press safety standards
- Anti-tie-down feature prevents unintended actuation on reset
- Constant fault detection — active at all times
Installation and Setup Guide
Air Line and Filter Preparation
Before installation, blow all air lines clean of contaminants. Install a 5-micron rated air filter at the inlet line close to the valve. Use lines of adequate size without restrictions at all ports.
Reset Port Configuration
If the DM2® Series D is not equipped with an on-valve reset solenoid, the RESET port must be supplied from an external 3/2 normally closed valve. Reset signals must be momentary. The RESET port line must be free of restrictions and of adequate size.
Base Mounting and Pipe Installation
Install the base first. For pipe threads, engage one turn, apply thread sealant (tape not recommended), then tighten. For parallel threads, no sealant. Blow debris from all piped lines with compressed air before installing the valve on the base.
Press Valve Testing Procedure
After installation and before connecting to the press: (A) Energize both solenoids simultaneously, then de-energize one — valve should lock out. (B) Energize both solenoids — valve remains locked out. (C) De-energize both solenoids and reset valve. (D) Repeat with the other solenoid. (E–F) Same as D–C. After passing all tests, normal press operation may be initiated following all applicable press safety procedures.
Why Choose ROSS Controls
ROSS Controls invented the modern pneumatic press safety valve concept and has been the industry standard for press clutch/brake valve technology for over 100 years. The DM2® Series D is the result of continuous engineering refinement, incorporating the latest crossflow and monitoring technology in a self-contained package that simplifies press system design. Call 1-800-GET-ROSS or visit www.rosscontrols.com.
Download This Document
The official DM2® Series D Press Double Valves Installation Instructions (document SS293) covers Basic Sizes 2 through 30 with complete specifications, timing charts, and test procedures for press clutch/brake applications.
Download PDF: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/14/ROSS_DM2_Series_D_Double_Valves_Installation_Instructions_SS293.pdf.pdf
Related Products and Resources
- DM2® Series D Operating Instructions — Complete operation guide RC-DM2DF-OI (doc 85)
- 35 Series SERPAR® Double Valves — Press double valves with monitors (doc 81)
- 35 Series SERPAR® Double Valves with Dual Monitoring — CSA Z142 compliant (doc 82)
- 35 Series CrossFlow® Double Valves — Operating instructions (doc 86)
- ROSS 55 Series Silencers — Factory-equipped exhaust silencers
- L-O-X® Lockout Valves — Press energy isolation for LOTO
Frequently Asked Questions
Q: Why is the DM2® Series D required for press clutch/brake applications instead of Series C?
A: The DM2® Series D has specific flow, exhaust, and lockout characteristics engineered for mechanical power press clutch/brake control. The DM2® Series C is expressly not for press clutch/brake use. Only the Series D meets OSHA 29 CFR 1910.217 and ANSI B11.1 requirements for press safety valves.
Q: What basic sizes are available for the DM2® Series D?
A: The DM2® Series D is available in Basic Sizes 2, 4, 8, 12, and 30, covering the full range of mechanical power press flow requirements from small high-speed presses to large heavy-duty presses.
Q: Does the DM2® Series D require an external monitoring system?
A: No. The DM2® Series D is completely self-contained and does not require an external monitoring system. Its crossflow passages and internal pilot monitoring provide all necessary fault detection per Category 4 requirements.
Q: What happens if the supply pressure is removed while the DM2® Series D is energized?
A: Turning off supply pressure while the valve is energized will result in a fault condition, requiring a reset before the valve can resume normal operation. This is shown in the DM2® Reset Timing Chart in the operating instructions.
Q: Can the DM2® Series D reset solenoid be mounted backwards?
A: If the reset solenoid is mounted backwards, energizing it will release air through its exhaust port (through the nut on the stem) and no reset action will occur. Verify correct solenoid orientation during installation.
Q: What is the discordance detection time for the DM2® Series D?
A: The DM2® Series D detects asynchronous valve element movement within approximately 125 milliseconds. This timing is preset by restricting orifices and chambers in the pilot air circuit.
Q: What does the status indicator option do on the DM2® Series D?
A: The optional status indicator uses a pressure switch with 4 contacts to signal the press control system that a fault/lockout has occurred. Contacts 1–2 are normally closed when depressurized; contacts 1–3 are normally open when pressurized (normal operation).
Q: What standards does the DM2® Series D comply with?
A: The DM2® Series D complies with ISO 13849-1 (Category 4), OSHA 29 CFR 1910.217 (mechanical power presses), ANSI B11.1, and CSA Z142. It is protected by U.S. Patents 6840258 and 6840259 and worldwide patents.