ROSS Controls acquires Michigan-based DECCO

ROSS Controls announced that it acquired the assets of the Detroit Coil Co., known in the marketplace as DECCO, on December 30, 2011. The history of the two companies has been intertwined, as DECCO has supplied components to ROSS for many decades.

ROSS, headquartered in Troy, Mich., designs and manufactures precision pneumatic valves, control systems and related products. Since 1921, ROSS has offered these products to the general fluid power industry and industries as diverse as metal forming, aluminum, glass container, steel and safety.

DECCO, with a history dating to 1912, manufactures coils and solenoids for a broad range of industry-specific applications. DECCO maintains offices in Ferndale, Mich. and operates a coil winding facility in Frankfort, Mich. and a screw machining facility in Benzonia, Mich.

Growth and opportunity lie ahead. DECCO expands ROSS’ product portfolio and provides additional avenues for expansion into electronics. For DECCO, the ROSS group provides access to new and untapped global markets.

Over the next several months, teams will be working to optimize the collective strengths of the two companies.

ROSS Controls

DECCO

Energy isolation for washdown applications

Building on its rugged Stainless Steel L-O-X lockout and exhaust valve, ROSS Controls is now offering a control reliable energy isolation solution specifically designed for sensitive washdown applications. ROSS has assembled some of its most popular products into a fluid and particulate resistant stainless steel cabinet to meet the need for uncontaminated fluid power control in industries such as food, beverage and chemical processing,

The Control Reliable Washdown cabinet incorporates:

• A 316 Stainless Steel L-O-X lockout and exhaust valve (on the exterior)
• A combination filter/regulator for particulate removal and pressure control
• A Category-4 DM2 double valve with dynamic monitoring and memory for air entry control
• A ready-to-mount stainless steel cabinet with a sloped top to avoid liquid accumulation

The self-draining Stainless Steel L-O-X valve is mounted on the exterior of the cabinet for quick access. It offers an easy-to-identify shape, tamper-proof locking mechanism, a large exhaust port for rapid pressure relief and simple push/pull operation—all of which meet OSHA, ANSI and CSA requirements. Its durable fluorocarbon seals resist contaminant ingression which is important in applications requiring consistent protection.

Because each cabinet is designed to customer specifications, the double valve used can be Category 2, 3 or 4—whatever is dictated by the customer’s thorough risk assessment. Further modifications can be made, depending on the application’s specific needs. Optional stainless steel silencers and pneumatic energy release verification products are also available for additional safety enhancement.

To learn more about how ROSS’ Control Reliable Washdown cabinet can help you maintain a productive and contaminant free production line, contact your local ROSS distributor or download ROSS’ brochure or Catalog 104.

ROSS Controls

Double valves for clutch/brake circuits

Mechanical press safety standards and good practices require several things in the event of a failure within the valve that controls a pneumatic clutch and brake:

• Air must be exhausted quickly to ensure fast stopping time.
• A monitor must take action to prevent further operation of the press.
• A method to alert personnel should be incorporated.

Double valves, or dual valves, have all of these features and have understandably thus become the press industry’s safety standard for clutch and brake control. These valves incorporate two valve elements which are independently controlled by two solenoid pilots within one valve body. The two valve elements share common inlet, outlet and exhaust ports. When the pilots are simultaneously energized, the elements operate so that the valve functions as a 3/2 normally closed valve.

Double valves, such as the ROSS DM2 Series D products, have built-in self monitoring and can send a signal back to the press controls in case of a valve malfunction. Each independent valve element monitors and cross-checks the operation of the other on each cycle, so that if one side fails to operate properly the valve immediately exhausts the downstream volume to less than 1% of supply pressure. The built-in monitor places the internal elements into a “locked-out” condition which prevents further operation of the valve or the press. A momentary reset signal is required to clear the valve fault and continue operation. An optional status indicator switch can provide “go” or “faulted” signals.

Because double valves provide a level of safety for mechanical press/clutch brake circuits that single element valves, even when externally monitored, simply cannot provide, they are known as “control reliable.” Control reliability is defined as “the capability of a device or system to stop or prevent initiation of hazardous motion in the event of a single component failure within the device or system”. Control reliable devices can be applied anywhere there could be exposure to catastrophic injury. Standardizing on double valves such as the ROSS DM2 Series D will simplify circuits and add a significant measure of safety.

Control reliablility requires:
• Redundancy
• Monitoring
• Further operations to be inhibited
• A defined action to reset
• Failing to a “SAFE” condition

Ross Controls

Valves for leak testing

Perhaps the most important factor in leak testing is the valve used to leak test. If the valve is not reliably leak tight itself, the testing efforts are a waste of time. ROSS’ high-flow, bubble tight Dale Series LT, CX and LX valves and manifolds have patented poppet design and exceptional sealing capabilities.

The Dale Series LT, CX and LX valves help streamline processes with their high flow (thus reducing testing time) and offer a broad pressure range of high vacuum up to 250 psi for flexibility. The LT, CX and LX valves are pressure independent so that pressure or vacuum can be applied to any port at any time. The valves feature low wattage coils that reduce energy consumption and help avoid unnecessary valve heat. For further convenience, these bi-directional valves are offered with compact manifolds which eliminate piping (and potential leak paths) and spacing between valves, and provide simplified installation.

Beyond their basic leak testing proficiency, the Dale Series LT, CX and LX valves are versatile and provide many application-specific benefits. In channel select applications, for example, customers are able to test multiple parts at a time or multiple chambers in a single part. And with bypass fill and exhaust applications, the Dale Series valves’ high-flow design can improve cycle time and be used as an exhaust valve, helping prevent contamination to other units.

ROSS Controls

Risk assessment—safety exhaust considerations

When evaluating a production system’s adherence to safety standards, electrical considerations are usually the top priority. A thorough risk assessment, however, requires that the fluid power components also be reviewed, especially considering they are often the final control element.

One of the most important factors in any pneumatic safety system is the machine stopping time. In the case of a sticky directional control valve, for example, cylinder motion could continue until the supply pressure is exhausted. Because of this, the valve exhaust response time is a critical factor in maintaining a safe stopping time. The term “safe stopping time” (per the ISO-Safety Related Parts of the Control System standard) means that the machine must be able to stop in a time period such that no worker should be able to reach a hazard area before the machine has time to stop. The faster the safety exhaust valve can dump the pressure from the system, the faster the machine will stop. This depends on the individual machine, but a faster stopping time means that the guards could be located closer to the machine, thus, allowing faster machine access and freeing up valuable floor space.

Valve exhaust time is a function of the response time and the flow rate. A valve that is slower to respond will have a longer exhaust time, and, potentially, a longer machine stopping time than a valve with the exact same C_V rating. Manufacturers usually provide flow charts or C_V data on their safety valves representing normal operation as well as flow during a faulted condition. Always consult this data in order to choose an appropriately sized valve for your safety system’s required stopping time.
The faulted response times of exhaust valves are particularly important attributes when serious hazards exist. A faulted valve will always increase the exhaust time and potentially the machine stopping time. The faulted valve response time depends entirely upon how a valve is constructed. Therefore, choosing a product designed to minimize these times is vital.

The ROSS DM2 Series C size 4 valves (½” port size) will increase exhaust response time by less than 33% in a faulted state, whereas other competitive valve designs are known to increase the exhaust response time by 60 to 80% (based on published data). For example, a 100 milliseconds exhaust time in a system with 30 in.³ of downstream system volume would increase to less than 133 milliseconds during a fault condition with the ROSS valve, or 160 to 180 milliseconds with a different company’s product. Due to the potential for injury, damage to machinery, and downtime, these values must be seriously considered in a safety system design.

ROSS Controls

Pneumatic Safety Certifications updated with Ross Controls

TROY, MI – ROSS CONTROLS is pleased to announce that its DM2® Series C safety valves have received third-party certification from the BG (Berufsgenossenschaften- German Institute for Occupational Safety and Health). On July 8, 2009, the BG deemed the DM2® Series C products suitable for ISO 13849-1:2006 Category 4 PL e applications. The ISO 13849-1:2006 standard (Safety of Machinery, Safety-related Parts of Control Systems) will replace the EN 954-1 standard as of November 30, 2009. This certificate is available on the ROSS Web site at www.rosscontrols.com or upon request from ROSS Customer Services.

All valves in the ROSS DM2® product line meet global requirements for machine safety and are commonly used for exhausting the downstream air to help meet stop-time requirements in machine guarding applications. Because many safety systems incorrectly focus solely on the electrical design and overlook mechanical elements, ROSS created the DM2® pneumatic double valve family to address this issue knowing that effective safety systems do not end at the electrical wire.

For enhanced performance and value, memory, monitoring, and airflow control functions are simply integrated into two identical valve elements. DM2® pneumatic safety valves lock out due to asynchronous movement of valve elements during actuation or de-actuation, resulting in a residual outlet pressure of less than one percent of supply. Overt action is required for reset, and reset can only be accomplished by applying a remote air signal or by energizing the integrated electrical (solenoid) reset. These ROSS safety valves are base-mounted and are available in 1/2” to 1-1/2” ports sizes with NPT or BSPP threads.

Additionally, all DM2® valves will be labeled with the CE (Conformite Europeenne) mark to comply with the New Machinery Directive (2006/42/EC) that takes effect in the European Union as of December 29, 2009. This directive defines the requirements for the CE marking of products, requires the CE mark on safety components, and specifically includes “…valves with additional means for failure detection intended for the control of dangerous movements on machinery.” The “Declaration of Conformity” document is available on the ROSS Web site at www.rosscontrols.com or upon request from ROSS Customer Services.