United States

Hazardous Location Valves [21 Series] 2/2, 3/2, 4/2 Functions

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Product Catalog
  • Perpendicular poppet face seals that creates high-flow and positive sealing
  • Differential piston design that delivers fast and consistent response times
  • Overwhelming shifting forces that provides no-stick operation
  • High velocity air flow aAcross poppet seats that allows self-cleaning and strong dirt tolerance
  • Superior internal guidance system and self-compensating seals that deliver long-life
  • Explosion-proof coils that contain any spark originating from within the coil or housing preventing the ignition of any flammable material in the surrounding environment, resulting in a larger explosion

 

Explosion-Proof Safety Function

Valves are equipped with explosion-proof coils for use in hazardous locations to prevent potentially explosive situations.

 

The 21 Series explosion-proof solenoid pilot controlled valves are ideal for low temperature applications in a wide range of industries and environments where safety from electrical ignition of flammable gases, vapors, flammable liquids, combustible dust, or easily ignitable fibers is a concern.

Series Overview

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Product Overview

The ROSS Controls 21 Series Hazardous Location Valves are inline poppet directional control valves engineered for classified hazardous areas where flammable gases, vapors, combustible dusts, or ignitable fibers present ongoing explosion risk, and where the operating environment may also impose low-temperature conditions. Available in 2/2, 3/2, and 4/2 valve functions across three body sizes with flow capacities up to 28 Cv (27,700 Nl/min), these valves combine the ROSS 21 Series perpendicular poppet design with CSA/FM explosion-proof coils, ATEX-certified coils, and intrinsically safe coil options. The 21 Series is specifically noted for its performance in low-temperature applications down to -4 F (-20 C) ambient.

The explosion-proof coil design physically contains any internal electrical fault within the coil housing, preventing flame propagation to the surrounding flammable atmosphere. CSA certification covers Class I, Division 1, Groups A, B, C, D; Class II, Division 1, Groups E, F, G; and Class III. FM approval covers the same North American classifications. ATEX-certified coils extend the protection to European Zone 1 and Zone 2. Intrinsically safe coil options limit the available electrical and thermal energy in the control circuit to levels inherently below ignition thresholds under all fault conditions, providing the maximum available degree of electrical protection in Division 1 classified areas.

The core mechanical design of the 21 Series Hazardous Location valve leverages the perpendicular poppet face seal geometry that is the defining performance attribute of the ROSS 21 Series platform. The poppet closes at 90 degrees to the flow axis, creating a high-velocity air stream across the seating surfaces on each cycle. This engineered flow path generates self-cleaning action that maintains sealing integrity in contaminated industrial environments. The differential piston actuator generates overwhelming shifting forces that ensure positive, no-hesitation actuation even after extended equipment downtime, a critical requirement in hazardous location installations where pre-startup valve function verification is a safety step.

Three body sizes cover port configurations from 1/4" to 1-1/2" in both NPT and G (BSPP) thread forms. The 21 Series Hazardous Location valve is the appropriate selection when Class I, Division 1 or ATEX Zone 1 certification is required within the port size range of the 21 Series platform. For larger port size requirements (up to 2-1/2"), the 27 Series Hazardous Location valve extends the certified product family to higher flow applications.

Key Engineering Features

  • Explosion-Proof Coils for CSA/FM Classified Locations - CSA and FM approved explosion-proof coil housings certified for Class I, Division 1, Groups A, B, C, D; Class II, Division 1, Groups E, F, G; and Class III hazardous location service. The encapsulated coil design (encapsulation 'm' per CAN/CSA E79-18-95) confines any internal electrical fault within the coil body, preventing flame transmission to surrounding classified atmospheres.
  • ATEX Certification for European Zone 1 and Zone 2 - ATEX-certified coils rated for II 2 G Ex mb IIC T5 classification, covering European Zone 1 and Zone 2 hazardous areas with the most demanding IIC gas group (hydrogen, acetylene). Coils certified per ATEX Directive 2014/34/EU with complete declaration of conformity documentation.
  • Intrinsically Safe Coil Option - Intrinsically safe coils rated for Class I, II, III, Division 1, Groups A through G with T5 temperature classification. Energy-limited circuit design prevents spark or thermal event capable of causing ignition under any single fault condition. For use with a compatible IS barrier in the control circuit.
  • Perpendicular Poppet Face Seals - Creates high-flow capacity with positive shutoff and near-zero leakage. The perpendicular sealing geometry directs high-velocity air across poppet seats on each shift, providing continuous self-cleaning action that maintains sealing integrity in contaminated compressed air environments typical in chemical, mining, and grain handling facilities.
  • Differential Piston Design for Fast, Consistent Response - Surface areas of the piston poppet, exhaust poppet, and inlet poppet are precisely engineered to generate strong shifting forces in both directions throughout the valve life. Fast, consistent response times are maintained regardless of operating pressure fluctuation, temperature variation, or minor contamination in the pilot air path.
  • Overwhelming Shifting Forces for No-Stick Operation - The differential force margin is intentionally large relative to spring return load, ensuring the valve shifts positively from idle even after extended downtime in cold, condensate-laden, or contaminated environments. This feature is essential in hazardous location installations where stuck-valve failures require immediate maintenance response in classified areas.
  • Low Temperature Capability to -4 F (-20 C) - The 21 Series Hazardous Location valves are specifically engineered and rated for low-temperature applications. Buna-N seal materials maintain sealing flexibility and performance down to -4 F (-20 C) ambient, covering arctic outdoor installations, refrigerated storage facilities, and cold-climate process plants that also require hazardous area certification.
  • Self-Compensating Seals for Extended Service Life - Superior internal guidance system automatically adjusts poppet stroke length as seals experience normal wear, maintaining consistent leak-free performance over millions of operating cycles. Extended service intervals reduce the frequency of planned maintenance entries into classified hazardous areas, lowering lifetime safety exposure.
  • Three Body Sizes for Flexible Flow Capacity - Available in 3/8" (Basic Size 1), 3/4" (Basic Size 2), and 1-1/4" (Basic Size 3) body sizes, covering port configurations from 1/4" through 1-1/2" and flow capacities from approximately 2.6 Cv to 28 Cv. All three body sizes are available with all coil certification options.
  • NPT and G Thread Options - Both NPT and G (BSPP) thread variants are available with CSA/FM and ATEX certifications, allowing the same certified valve family to be specified for both North American and international installations without separate product lines or approval reviews.
  • Non-Locking Manual Override - Standard on all solenoid pilot controlled models. Allows manual valve actuation during commissioning and troubleshooting without electrical power. The non-locking design auto-returns to solenoid control when released, preventing accidental position lock-in during maintenance procedures in hazardous areas.

Technical Specifications

General Specifications

Parameter Specification
Valve Functions 2/2 (NC/NO), 3/2 (NC/NO), 4/2
Construction Poppet
Actuation Solenoid Pilot Controlled; Pressure (Pneumatic) Controlled
Body Sizes 3/8" (Basic Size 1), 3/4" (Basic Size 2), 1-1/4" (Basic Size 3)
Inlet/Outlet Port Sizes 1/4" to 1-1/2" (NPT or G)
Maximum Flow - 3/8" Body 2.6 to 4.6 Cv (2,600 to 4,600 Nl/min)
Maximum Flow - 3/4" Body 6.3 to 10 Cv (6,200 to 10,000 Nl/min)
Maximum Flow - 1-1/4" Body 19 to 28 Cv (19,000 to 28,000 Nl/min)
Operating Pressure 30 to 150 psig (2.1 to 10 bar)
Pilot Supply Must be equal to or greater than inlet pressure; internal or external (field-convertible)
Flow Media Filtered compressed air
Mounting Inline; vertical with pilot on top is preferred
Valve Body Material Cast aluminum
Poppet/Spool Material Stainless steel
Seal Material Buna-N
Thread Types NPT (standard); G / BSPP (prefix D to model number)
Manual Override Non-locking button (solenoid models)
Electrical Connection 1/2" conduit with 30" leads
Duty Rating Continuous duty
Enclosure Rating IP65 per IEC 60529

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Temperature Ratings

The 21 Series Hazardous Location valves are rated for low-temperature applications where both hazardous area certification and cold-weather seal performance are required. Ambient temperature limits differ from media temperature limits because the solenoid coil thermal rating restricts the ambient range. Pressure-controlled (air pilot) variants are not subject to coil thermal constraints.

Configuration Ambient Temperature Media Temperature
Solenoid Pilot Controlled (All Coil Certifications) 4 to 140 F (-20 to 60 C) 4 to 175 F (-20 to 80 C)
Pressure (Pneumatic) Controlled 4 to 175 F (-20 to 80 C) 4 to 175 F (-20 to 80 C)

 

 

 

 

 

 

Important: For media temperatures below 40 F (4 C), compressed air must be free of water vapor to prevent ice formation inside the valve. Dry the compressed air supply to a dew point below the minimum operating temperature. In low-temperature outdoor installations, use insulated or heat-traced supply lines to prevent condensate accumulation between the dryer and the valve.

 

Electrical Data (Solenoid Pilot Valves)

Explosion-proof CSA/FM and ATEX coils have different power ratings due to their distinct enclosure construction methods. Intrinsically safe coils have the lowest power consumption. All coil types are rated for continuous duty. Coil power ratings are verified at the specified voltage; applying voltage outside the rated tolerance range can cause coil failure and compromise explosion-proof enclosure integrity.

Voltage Power Consumption
24 VDC (Explosion-Proof CSA/FM) 4.6 watts
120 VAC, 60 Hz (Explosion-Proof CSA/FM) 6.8 VA
24 VDC (ATEX Certified) 3.5 watts
120 VAC, 60 Hz (ATEX Certified) 3.4 VA
24 VDC (Intrinsically Safe) 1.6 watts
12 VDC 4.6 watts
240 VAC, 60 Hz 6.8 VA

 

 

 

 

 

 

 

Electrical Connection Options

Connection Type Coil Code
1/2" Conduit with 30" Leads - Explosion-Proof CSA/FM Standard (no suffix)
1/2" Conduit with 30" Leads - ATEX Certified Suffix -A
1/2" Conduit with 30" Leads - Intrinsically Safe Suffix -N

 

 

 

 

Flow Performance Data

Flow performance data for representative 21 Series Hazardous Location valve configurations. Cv values are identical between the hazardous location and standard 21 Series models because the valve body and poppet assembly are unchanged; only the solenoid pilot assembly differs. Response time formula: Response Time (ms) = M + (F x V).

Body Size Inlet/Outlet Port Exhaust Port Cv (NC) Cv (NO) M (ms) Weight lb (kg)
3/8" 1/2" NPT 1/2" 2.6 4.6 10 2.1 (1.0)
3/4" 3/4" NPT 1" 6.3 10 14 4.3 (2.0)
1-1/4" 1-1/2" NPT 1-1/2" to 2-1/2" 19 28 26 11.4 (5.2)

 

 

 

 

 

 

Response Time Formula: Response Time (ms) = M + (F x V), where M is the minimum response constant (ms), F is the fill or exhaust factor (ms/cubic inch), and V is the downstream volume in cubic inches to be filled to 90% of supply pressure or exhausted to 10% of supply pressure. M and F values for each body size and valve function are published in the ROSS 21 Series catalog.

 

Certifications & Compliance

Certification/Standard Detail
FM Approval (Explosion-Proof) Factory Mutual approved for Class I, Division 1, Groups A, B, C, D; Class II, Division 1, Groups E, F, G; Class III. Non-incendive for Class I, Division 2, Groups A, B, C, D. Temperature classification T4, Ta = 60 C. FM Class 3600, 3611, 3615, 3810.
CSA Certification (Explosion-Proof) Canadian Standards Association certified per CSA C22.2 No. 0-10, No. 25-1966, No. 142-M1987, No. 213-M1987; CAN/CSA E79-0-95; CAN/CSA E79-18-95 (Encapsulation 'm'). Approved for Class I, Division 1, Groups A, B, C, D; Class II, Groups E, F, G; Class III; Class I, Division 2.
ATEX Certification II 2 G Ex mb IIC T5 (Zone 1 and Zone 2). Certified by TUV Rheinland or TUV SUD per ATEX Directive 2014/34/EU for explosive gas atmosphere applications including hydrogen and acetylene (Group IIC).
Intrinsically Safe Option IS coils rated for Class I, II, III, Division 1, Groups A through G, T5 temperature class. Requires use with a compatible CSA or FM approved IS barrier. Energy levels inherently incapable of ignition under normal or fault conditions.
Enclosure Rating IP65 per IEC 60529. Dust-tight and protected against low-pressure water jets.
Functional Safety The standard 21 Series poppet valve platform is TUV Rheinland certified to SIL 2 (IEC 61508) and PL c (EN ISO 13849-1) in singular application. Redundant configurations achieve SIL 3 and PL e.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Typical Applications & Industries

Oil and Gas Production and Upstream Processing

  • Wellhead control and emergency shutdown (ESD) valve actuator pilots in Class I, Division 1 locations classified for hydrocarbon gas at atmospheric conditions. The 21 Series body size range accommodates actuator sizing requirements for small to medium process valves at wellhead pressure control assemblies.
  • Gas gathering and compression station pneumatic controls where methane and other light hydrocarbon vapors create persistent classified atmospheric conditions. The low-temperature capability to -4 F (-20 C) covers outdoor installations in northern climates.
  • Offshore platform pneumatic actuator controls in salt-spray environments with Class I, Division 1 or Zone 1 classification. Both NPT and G thread options accommodate the mixed international equipment standards common on offshore platforms.
  • Arctic pipeline block valve and control valve actuator pilots where -4 F (-20 C) ambient performance and Division 1 certification are simultaneous requirements.

Chemical and Petrochemical Processing

  • Process reactor and vessel pneumatic actuated valve controls in Class I, Division 1 areas where volatile organic compound handling creates sustained flammable vapor concentrations. The ATEX IIC certification covers Group C and D equivalent solvents as well as Group A/B hydrogen and acetylene environments.
  • Solvent recovery and recycling system valve actuation in pharmaceutical and specialty chemical manufacturing where ketone, ester, aromatic, and chlorinated solvent vapors define area classification.
  • Emergency isolation and pressure relief system pneumatic controls requiring certified explosion-proof coils and reliable poppet valve actuation under emergency conditions.
  • Chemical powder and catalyst handling systems in Class II combustible dust environments requiring the CSA/FM dust-ignition-proof coil rating.

Wastewater Treatment and Biogas Facilities

  • Anaerobic digester and biogas collection system valve actuation in Class I, Division 1 locations classified for methane and hydrogen sulfide mixtures generated during organic waste decomposition.
  • Sludge handling and dewatering automation in facilities where methane accumulation in enclosed structures creates persistent Division 1 classification.
  • Leachate collection and treatment system valve controls at landfill facilities where variable methane concentrations require Division 1 rated pneumatic components throughout the collection infrastructure.

Food, Grain, and Distillery Processing

  • Grain elevator leg and conveying system valve controls in Class II, Division 1 locations classified for grain dust. The explosion-proof coil rating covers Groups E, F, and G dust classifications applicable to grain, flour, sugar, and starch dust environments.
  • Alcohol distillation and fermentation facility automation where ethanol vapor creates Class I, Division 1 conditions during production operations. The 21 Series compact body sizes fit within the tight equipment layouts of distillation column and fermentation vessel control panels.
  • Brewing and winery carbon dioxide handling systems where CO2 accumulation combined with ethanol vapor in enclosed spaces can create classified atmospheres requiring explosion-proof valve controls.

Mining and Mineral Extraction

  • Underground coal mine pneumatic equipment controls in methane-classified atmospheres. CSA/FM Group A approval covers methane, which is the primary hazardous gas in underground coal mining operations.
  • Potash and mineral fertilizer handling systems in Class II, Division 1 combustible dust environments where fine mineral dust creates explosion risk at handling and transfer points.
  • Surface hardrock mine pneumatic actuator controls in blasting chemical storage areas classified for explosive gas groups requiring Division 1 or ATEX Zone 1 certified components.

Paint, Coatings, and Solvent Manufacturing

  • Automated spray booth pneumatic controls in Class I, Division 1 areas classified for continuous solvent vapor presence during spray operations.
  • Solvent blending and mixing room pneumatic valve actuation where flammable solvent vapor concentrations within the flammable range can exist during normal processing.
  • Coating material tank farm transfer and loading automation in facilities where ATEX or CSA/FM certified pneumatic components are required by facility safety assessments.

Ordering and Model Number Configuration

The ROSS 21 Series Hazardous Location valves use the same base model number structure as the standard 21 Series, with coil certification designated by suffix. The example below illustrates a 3/2 NC solenoid pilot controlled valve in the 3/4" body size for 24 VDC service with an explosion-proof CSA/FM coil.

 

Model Number Structure: 21 7 3 B 6002 W

 

21 Series designation (21 Series)

 

7 Actuation type

7 = Solenoid Pilot Controlled

5 = Pressure (Pneumatic) Controlled

 

3 Valve function

1 = 2/2 Normally Closed

2 = 2/2 Normally Open

3 = 3/2 Normally Closed

4 = 3/2 Normally Open

6 = 4/2

 

B Revision level

 

6002 Body/port size code (second digit 2 = NPT hazardous location)

4002 = 3/8" body (Basic Size 1) - 1/4" through 1/2" ports

6002 = 3/4" body (Basic Size 2) - 1/2" through 1" ports

8002 = 1-1/4" body (Basic Size 3) - 1" through 1-1/2" ports

 

W Voltage code

H = 12 VDC

W = 24 VDC

Z = 120 VAC, 60 Hz

Y = 240 VAC, 60 Hz

 

Coil Certification Suffix:

(none) = Explosion-Proof CSA/FM

A = ATEX Certified

N = Intrinsically Safe

 

G Thread Prefix: Add 'D' before model number for G (BSPP) threads

Example (NPT, Explosion-Proof): 2173B6002W

Example (G thread, ATEX): D2173B6002W-A

Example (NPT, Intrinsically Safe): 2173B6002W-N

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Voltage codes: H = 12 VDC, W = 24 VDC, Z = 120 VAC/60 Hz, Y = 240 VAC/60 Hz. Contact ROSS Controls for additional voltage requirements.

For G (BSPP) thread versions, add the prefix 'D' before the model number (e.g., D2173B6002W). G thread models carry the same certification approvals as NPT models.

Coil certification suffix: no suffix = Explosion-Proof CSA/FM (standard); -A = ATEX certified; -N = Intrinsically Safe. Select the certification matching the site hazardous area classification and the applicable electrical standard (NEC, CEC, IEC 60079, or ATEX).

The valve body, poppet assembly, and all wetted components are identical between the standard 21 Series and the hazardous location 21 Series. Body service kits are interchangeable, which allows a single maintenance spare to cover both standard and classified-area installations.

External pilot supply configurations are ordered by specifying pilot type code at time of order. Field conversion from internal to external pilot is also possible by relocating the pipe plug per the installation instructions.

Accessories

Exhaust Silencers

Aluminum exhaust silencers reduce exhaust noise at the valve exhaust port. Silencers contain no electrical components and do not require separate hazardous location certification. Flow capacity must equal or exceed the valve exhaust capacity. Available for 1/2" through 1-1/2" NPT or G thread.

Port Size Thread Avg Cv (Nl/min) Model (NPT) Model (G)
1/2" Male NPT/G 6.8 (6,700) 5500A4003 D5500A4003
1" Male NPT/G 18 (18,000) 5500A6003 D5500A6003
1-1/2" Female NPT/G 39 (38,000) 5500A8001 D5500A8001

 

 

 

 

Warning: Exhaust silencer flow capacity must equal or exceed the valve exhaust capacity. Contaminated or undersized silencers create back pressure on the exhaust side of the poppet, reducing shifting force and potentially causing incomplete valve actuation.

 

Valve Body Service Kits

Complete valve body reconditioning kits containing poppets, spindle, all gaskets and seals, and installation instructions. Available for all three body sizes and all valve functions. Gasket and seal-only kits are available for routine preventive maintenance without full poppet replacement. Service kit model numbers are listed in the ROSS 21 Series catalog by body size and function.

 

Replacement Solenoid Pilots and Coils

Replacement solenoid pilot assemblies (model 1488G79, specify voltage) and replacement solenoid coils (model 409B33, specify voltage) are available for field service of the pilot assembly without requiring valve body replacement. Verify that replacement coils carry the appropriate hazardous location certification suffix for the installation.

 

Related Products & Accessories

Frequently Asked Questions (FAQ)

Q: What temperature range do the 21 Series Hazardous Location valves support?

A: Solenoid pilot controlled models are rated for ambient temperatures from -4 F (-20 C) to 140 F (60 C), and media temperatures from -4 F (-20 C) to 175 F (80 C). Pressure-controlled (air pilot) models without solenoid coils extend both ambient and media limits to 175 F (80 C). The low-temperature floor of -4 F is a key differentiator of the 21 Series compared to the 27 Series, which has a minimum operating temperature of 40 F (4 C). For applications requiring operation below -4 F, consult ROSS Controls for seal material and coil options.

Q: What is the minimum operating pressure for the 21 Series Hazardous Location valves?

A: The minimum operating pressure is 30 psig (2.1 bar) for all body sizes and valve functions. This minimum is higher than the 27 Series (15 psig for smaller body sizes) because the 21 Series poppet geometry requires a higher minimum differential to generate reliable shifting force at small body sizes. Verify that supply pressure never drops below 30 psig during system operation, including transient pressure dips during rapid actuator cycling.

Q: Which coil certification should I specify for a Class I, Division 1, Group C and D location?

A: For Class I, Division 1, Group C and D (typical for propane, hydrogen sulfide, ethylene), specify the standard explosion-proof CSA/FM coil (no certification suffix). This coil is FM and CSA approved for Groups A, B, C, D, which covers all standard flammable gas groups. If the site uses European ATEX classification instead of NEC/CEC, specify the ATEX-certified coil (suffix -A), which is rated to IIC gas group covering the same range of flammable gases.

Q: Can the 21 Series Hazardous Location valve be used in Class II combustible dust environments?

A: Yes. The explosion-proof CSA/FM coils are approved for Class II, Division 1, Groups E, F, G, covering metallic dusts (Group E), carbonaceous dusts such as coal (Group F), and grain or agricultural dusts (Group G). This makes the 21 Series Hazardous Location valves suitable for grain elevators, flour mills, and chemical powder handling facilities in addition to flammable gas applications. ATEX dust-classified Zone 21 and Zone 22 applications should reference the specific ATEX certificate for applicable dust groups.

Q: What is the difference between the 21 Series and 27 Series Hazardous Location valves?

A: The primary differences are body size range and low-temperature capability. The 21 Series offers three body sizes covering ports from 1/4" to 1-1/2" (Cv to 28) with a minimum operating temperature of -4 F (-20 C). The 27 Series offers nine body sizes covering ports from 1/4" to 2-1/2" (Cv to 82) with a minimum operating temperature of 40 F (4 C). Both series carry CSA/FM explosion-proof and ATEX certifications. Select the 21 Series when low-temperature performance is required; select the 27 Series when higher flow capacity or larger port sizes are needed.

Q: Do the 21 Series Hazardous Location valves require lubrication?

A: The valve body does not require air line lubrication. The poppet and seal design operates reliably on clean, unlubricated compressed air. If upstream system components require lubrication and lubricated air is supplied to the valve, use only petroleum-based oils with an aniline point between 180 F (82 C) and 220 F (104 C) at ISO 32 viscosity or lighter. Avoid oils with phosphate-type additives, which are incompatible with polyurethane valve components.

Q: Can the valve be converted between internal and external pilot supply in the field?

A: Yes. Field conversion from internal to external pilot supply is accomplished by relocating the pipe plug between the external pilot port (X-1) and the internal pilot passage, per the installation instructions included with the valve. No replacement parts or tools beyond a wrench are required. External pilot is useful when supply pressure varies below 30 psig, requiring a stable separate pilot source. Update the installation documentation to reflect the pilot configuration change.

Q: What conduit sealing requirements apply to the 21 Series Hazardous Location valves in NEC Class I, Division 1 locations?

A: NEC Article 501 requires an explosion-proof conduit sealing fitting (EYS or equivalent) within 18 inches of each conduit entry into an explosion-proof enclosure in Class I, Division 1 locations. The sealing fitting must be sealed with an approved compound before the conduit system is energized. The purpose is to prevent flame propagation through the conduit from the explosion-proof coil housing to unclassified areas or between explosion-proof enclosures. Verify conduit seal compound compatibility with installed wire gauge.

Q: Are replacement coils and service parts available with the required hazardous location certifications?

A: Yes. ROSS Controls provides replacement solenoid pilot assemblies (model 1488G79, specify voltage) and replacement solenoid coils (model 409B33, specify voltage) as service parts. When ordering replacement coils for hazardous location installations, specify the required certification suffix (-A for ATEX, -N for IS) to ensure the replacement carries the appropriate approval markings. Valve body service kits contain non-electrical components and do not require hazardous location certification.

Q: What is the duty rating for the solenoid coils?

A: All explosion-proof, ATEX, and intrinsically safe coils for the 21 Series are rated for 100% continuous duty. The coil thermal design and enclosure construction accommodate sustained energization without exceeding the coil temperature class (T5 = 100 C maximum surface temperature). Verify that the control system does not impose unnecessary prolonged energization when the valve function requires only momentary actuation, as continuous duty rating reflects thermal design rather than a recommendation for continuous energization in all applications.

Q: What happens to valve performance at the minimum -4 F operating temperature?

A: At -4 F (-20 C), Buna-N seal materials remain adequately flexible to maintain sealing integrity under operating pressure. The valve will shift reliably provided compressed air is free of water vapor. The differential piston design's overwhelming shifting force provides additional margin against seal stiffness at low temperatures. Do not apply compressed air containing entrained moisture or liquid water at temperatures below 40 F, as ice formation in the poppet area will cause valve malfunction. A properly sized refrigerated or desiccant air dryer upstream is mandatory for sustained low-temperature operation.

Q: How do I verify that installed valves in hazardous areas are operating correctly without entering the area?

A: The solenoid coil energization state can be monitored externally through the control system I/O signal. For process diagnostic feedback, install position feedback switches on the downstream pneumatic actuator to confirm actuator response to each valve shift command. This closed-loop verification confirms not only that the solenoid is energized but that the valve is actually shifting and the downstream actuator is responding. ROSS does not recommend installing indicator lights in Division 1 locations without verifying that the indicator accessory itself carries the required hazardous location approval.

Q: Are CAD models available for the 21 Series Hazardous Location valves?

A: Yes. Downloadable CAD models are available for all 21 Series Hazardous Location valve variants at rosscontrols.com. The dimensional envelope of hazardous location models differs from standard 21 Series models due to the larger explosion-proof, ATEX, or IS coil housings. Use the hazardous location specific CAD model during machine design to ensure correct mechanical clearance and conduit routing allowances around the coil housing.

Installation & Maintenance Guidelines

  • Mount the valve inline with the preferred orientation being vertical, pilot assembly on top. This position promotes condensate drainage away from the valve internals and provides optimal thermal convection from the coil housing. Horizontal mounting is acceptable but avoid pilot-facing-down orientation in environments with liquid contamination risk.
  • Supply filtered compressed air. Install an upstream filter-regulator rated for 40-micron minimum filtration. Position the filter as close to the valve as practical to minimize unfiltered supply line volume. Wet or heavily contaminated air shortens seal life and can cause ice formation at low-temperature operating conditions.
  • Verify operating pressure remains within 30 to 150 psig (2.1 to 10 bar) throughout all system operating modes including transient pressure dips during rapid cylinder cycling. Operation below 30 psig minimum will result in incomplete valve shifting.
  • Install all conduit and electrical fittings per the applicable hazardous location electrical code before energizing the system. In NEC Class I, Division 1 locations, install explosion-proof conduit sealing fittings (EYS type) within 18 inches of every conduit entry into the coil housing. Fill sealing fittings with approved sealing compound before energizing.
  • Confirm solenoid voltage matches available supply voltage before making electrical connections. Voltage mismatch causes immediate coil failure. Verify voltage markings on the coil housing against the control panel supply voltage documentation before connecting.
  • Rotate the pilot assembly to the desired orientation (four positions at 90-degree increments) before sealing conduit fittings. Once conduit is sealed, reorienting the pilot requires breaking the conduit seal, which must be re-sealed before re-energizing in Class I, Division 1 service.
  • For low-temperature installations below 40 F (4 C), supply dry compressed air with a system dew point at least 10 F below the minimum expected operating temperature. Install a refrigerated dryer or desiccant dryer upstream with dew point monitoring to verify system performance. Moisture in compressed air at sub-freezing temperatures forms ice that causes valve malfunction.
  • Do not restrict the valve exhaust port with undersized silencers or piped exhaust lines with insufficient flow capacity. Restricted exhaust back pressure reduces poppet differential force and can prevent the valve from completing its shift. If the exhaust must be piped away from the valve, size the exhaust piping and any silencer to provide a Cv at least equal to the exhaust flow capacity of the valve.
  • For external pilot supply configurations, route pilot supply from a stable, regulated source that maintains pressure equal to or greater than inlet pressure at all times. Pilot supply pressure below inlet pressure will not generate sufficient differential force across the piston to shift the poppet.
  • Perform a pre-startup functional check using the non-locking manual override button before energizing the electrical system. Depress the manual override and confirm the downstream actuator responds correctly. Release and confirm the valve returns to its default position. This test verifies mechanical function without exposing the coil circuit to electrical stress and can be performed outside the classified area boundary if the actuator output is visible.
  • Use only petroleum-based lubricants if lubricating upstream mechanisms on the same air supply. Oils with phosphate-type additives are incompatible with polyurethane seals and will cause accelerated degradation of valve internals. Recommended lubricant: petroleum base oil with aniline point between 180 F (82 C) and 220 F (104 C), ISO 32 or lighter viscosity, applied at approximately one drop per minute.
  • During plant turnarounds or extended shutdown periods, cycle the valve manually using the override before returning to production service to confirm free poppet movement. Extended idle periods in cold, contaminated, or high-humidity environments can cause temporary sticking at seal interfaces. Manual cycling purges residual condensate and confirms actuation function before the system is returned to hazardous location service.

Warranty & Global Support

ROSS Controls provides a one-year warranty on all products, covering defects in material and workmanship from the date of purchase.

Global technical support is available through ROSS Controls offices in the USA (headquarters in Ferndale, Michigan), Canada, Brazil, Germany, France, United Kingdom, India, China, and Japan.

For hazardous location applications, ROSS Controls can provide copies of CSA/FM certificates, ATEX declarations of conformity, and applicable test reports for facility safety file documentation. Request certification documentation at the time of product order.

Contact ROSS Controls USA at (800) 438-7677 or visit rosscontrols.com for product configuration guidance, hazardous location application support, distributor locator, and technical service.

Download Catalog: https://www.rosscontrols.com/en/documents/384