RSe Series Double Valve Safety Category. 4 PL e, External Monitoring

Product Overview

The ROSS Controls RSe Series Double Valve is a redundant, spool-type pneumatic control valve designed to deliver the highest available safety performance - Safety Category 4, Performance Level e (PL e) per ISO 13849-1 and Safety Integrity Level 3 (SIL 3) per IEC 61508 - when used with a properly configured external monitoring system. The RSe Series is specifically engineered for safety circuits that must detect valve failures before they result in hazardous machine motion.

The RSe Series is constructed from two parallel spool-and-sleeve valve elements operating together as a single unit. Both solenoids must be simultaneously energized to actuate the valve - if either solenoid fails to energize or either spool fails to shift, the valve remains in the de-energized (safe) state. Each individual valve element is equipped with a PNP proximity sensor that monitors spool position. When both sensors are monitored on every actuation and de-actuation cycle by an external safety-rated controller, a diagnostic coverage (DC) of 99% is achieved.

The RSe Series overall valve function operates as a single solenoid pilot-operated, spring return 5/2 valve. Proper simultaneous actuation routes inlet pressure (port 1) to the cylinder extend port (port 4) while port 2 exhausts through port 3. When de-energized, port 1 routes to port 2 (cylinder retract) while port 4 exhausts through port 5. This configuration supports both standard cylinder control and specialized Safe Return and Safe Pressure Select applications.

The RSe Series is available in dual 3/2 and dual 5/2 spool configurations with base mounting and NPT or G (BSPP) thread options. Available in 1/8 inch, 1/4 inch, and 1/2 inch base sizes at 24 VDC, with automatic reset on solenoid de-energization. Certifications include CE, DGUV, CSA/UL, and EAC declarations.

Key Engineering Features

• Redundant Dual Spool Construction - Two parallel spool-and-sleeve valve elements must both shift simultaneously for the valve to actuate. A failure in either element leaves the valve in the de-energized safe state, providing inherent redundancy without external redundancy hardware.
• Simultaneous Dual Solenoid Actuation Required - Both solenoids must be energized concurrently to actuate the RSe valve. Single solenoid failure cannot produce an output, eliminating single-point failures from the actuation path.
• PNP Proximity Sensor Position Monitoring - Each spool element is equipped with an individual PNP proximity sensor that provides real-time spool position feedback. The external safety controller monitors both sensors to detect discordant or incomplete spool movement.
• 99% Diagnostic Coverage with External Monitoring - Monitoring both PNP proximity sensor outputs on every actuation and de-actuation cycle through an external safety-rated controller achieves a diagnostic coverage of 99%, meeting Category 4 PL e requirements.
• Safety Category 4 PL e, SIL 3 Capable - When used with proper external safety controls and monitoring, the RSe Series achieves Safety Category 4, PL e per ISO 13849-1 and SIL 3 per IEC 61508, the highest performance levels for pneumatic safety valves.
• Safe Return Dual Pressure Application Support - The RSe Series can control dual-pressure cylinder actuation - extending with pressure at port 3 and retracting with pressure at port 5 - for safe return applications where different pressures are required for advance and retract strokes.
• Safe Pressure Select Application Support - The RSe Series supports safe selection of the pressure applied to a machine operation, allowing the safety system to route the correct pressure level to actuators under monitored, redundant control.
• Automatic Reset on De-energization - The RSe valve automatically resets to its normal de-energized state when both solenoids are de-energized. No manual intervention is required to restore the valve to its ready-to-run condition after a normal stop.
• Base Mounted with Inlet/Outlet on Both Sides - Base-mounted design with inlet and outlet ports accessible from both sides provides flexible piping options. Captive valve-to-base mounting screws are included. Plugs for unused ports are provided.
• SISTEMA Library Available - Published SISTEMA data library available for download to support ISO 13849-1 PL verification and safety circuit documentation.

Technical Specifications

General Specifications

Flow Performance Data

Flow coefficient data for RSe Series double valves by base size. All flow values at 24 VDC, 145 psig max operating pressure.

Certifications & Compliance

Typical Applications & Industries

Mechanical Power Presses and Stamping

• Redundant air control for pneumatic clutch/brake mechanisms on mechanical power presses where Category 4 PL e is required by OSHA 29 CFR 1910.217 and ANSI B11.1 for full-revolution clutch presses.
• Dual-pressure safe return control on press cylinder circuits where the RSe routes full press force pressure at port 3 for the working stroke and a lower retract pressure at port 5 for the return stroke.
• Pilot control for hydraulic press over-pressure protection valves where redundant pneumatic actuation with external monitoring is required by the press safety control architecture.
• Die change and setup mode pressure reduction where the RSe Safe Pressure Select function routes reduced pressure to press actuators during manual tool setup operations.

Injection Molding and Plastics Processing

• Redundant control of mold clamp actuator pilot circuits on injection molding machines requiring Category 4 safety performance for the mold protection function.
• Safe pressure select control for core pull and side action actuators where different pressure levels are required for insert and extraction strokes under safety system control.
• Redundant shut-off on purge guard air actuators where Category 4 monitoring is required to ensure the guard cannot open while the barrel is at process temperature.

Robotic and Automated Assembly Cells

• Redundant pneumatic control for pneumatic robot arm actuators in collaborative robot cells where Category 4 PL e is required to prevent unexpected robot motion during collaborative operation.
• Safe pressure select for dual-force gripper actuators on industrial robots where low grip force is required for delicate parts handling and high grip force is required for heavy part transfer.
• Redundant control of pneumatic door and gate actuators on automated assembly cells with Category 4 safety interlocking requirements.

Safety Gate and Guard Locking Systems

• Redundant pneumatic control of safety gate locking mechanisms where Category 4 monitoring by a safety PLC ensures the gate cannot be unlocked while hazardous motion is present.
• Dual-pressure control of pneumatic guard actuators where low pressure is used for guard positioning and high pressure for lock confirmation, with the RSe monitoring both pressure states.
• Pneumatic interlocks on perimeter fencing around high-speed robot systems requiring the highest available category of safety control.

Metal Forming and Forging Operations

• Redundant pilot control of hydraulic press directional valves on forging presses where Category 4 pneumatic safety control is mandated by press safety standards and customer safety audits.
• Safe return control for die forging ram actuators where rapid ram retraction is required upon e-stop, with dual-pressure pneumatic control ensuring both forward and retract strokes are monitored.
• Blankholder and knockout actuator control on deep-draw presses using RSe redundant control to prevent uncontrolled actuator extension during die access.

Woodworking and Panel Processing Machinery

• Redundant pneumatic control for blade guard actuators and saw blade braking systems on CNC routing and sawing centers where Category 4 is required by EN 848 and similar woodworking machine standards.
• Safe control of pneumatic clamping systems on CNC nested-based processing centers where workpiece release during machining could result in projectile hazards.
• Pressure select control for edge-banding and finishing machine clamp actuators requiring different clamping forces for different panel thicknesses under monitored safety control.

Ordering and Model Number Configuration

RSe Series double valves are ordered by specifying the valve function (3/2 or 5/2), base size, thread type, and monitoring options. Example model numbers: RSe3EDA10A31P (Dual 3/2, 1/8 base, G thread), RSe6EDB20A31P (Dual 5/2, 1/4 base, G thread), RSe6EDB40A31P (Dual 5/2, 1/2 base, G thread).

All RSe Series valves operate at 24 VDC. No other voltage options are available.

Solenoid connection type is EN 175301-803 Form C on all models.

Feedback sensors use M8 connectors on all models. Ensure external safety controller has compatible M8 inputs.

NPT thread models are available - specify thread type at time of order.

For Safe Return Dual Pressure applications, confirm port 3 and port 5 pressure sources are separate and independently regulated.

Accessories

External Safety Monitoring Controller

The RSe Series requires an external safety-rated controller (safety PLC or dedicated safety relay module) to monitor both PNP proximity sensor outputs on every actuation and de-actuation cycle. The monitoring system must be capable of inhibiting valve operation upon detecting a fault. ROSS recommends consulting a qualified safety engineer for controller selection and safety circuit design.

M8 Sensor Cables

M8 connector cables are required to connect the PNP proximity sensors on each RSe valve element to the external safety monitoring controller. Cable length and shielding should be selected based on installation distance and electrical noise environment.

Related Products & Accessories

• SV27 Series Sensing Valve (Category 2 PL c) - 27 Series poppet sensing valve with DPST switch for Category 2 PL c applications with lower flow requirements. https://www.rosscontrols.com/en/series/1298-directional-control-valve-sv27-series
• 27 Series Soft Start EEZ-ON Valve - Soft start valve for controlled pressure buildup at machine startup. Safety Category 1, PL c. https://www.rosscontrols.com/en/series/1299-27-series-soft-start-eez-on-valve
• 77 Series Double Valve (Internal Monitoring, Auto Reset) - Self-contained monitoring double valve that does not require external monitoring controller. https://www.rosscontrols.com/en/series/1301-77-series-double-valve
• CrossMirror CM26 Series (Internal Monitoring, Manual Reset) - Self-monitoring double valve with dedicated manual reset for base-mounted applications. https://www.rosscontrols.com/en/series/1302-crossmirror-cm26-series-double-valves
• Lockout Valves (L-O-X, 15 Series) - Pneumatic lockout valves for OSHA-compliant energy isolation during maintenance. https://www.rosscontrols.com/en/series/1287-lockout-valves-15-series

Frequently Asked Questions (FAQ)

Q: What is a double valve and how does the RSe Series work?

A: A double valve contains two parallel spool valve elements in a single housing. In the RSe Series, both solenoids must be simultaneously energized to shift both spools and produce an output. If either solenoid fails to energize, or either spool fails to shift, the output is not produced and the system remains in or returns to the safe state. This redundancy eliminates single-point failures from the control path.

Q: Why is external monitoring required for the RSe Series?

A: The RSe Series is designed for external monitoring because the PNP proximity sensor signals are fed to an external safety-rated controller rather than a self-contained internal monitoring circuit. This allows the RSe to be integrated into a broader machine safety system where the monitoring controller also manages other safety functions, providing system-level diagnostic coverage and fault response.

Q: What safety performance level can be achieved with the RSe Series?

A: When used with a properly configured external safety monitoring system that monitors both PNP proximity sensors on every actuation and de-actuation cycle, the RSe Series achieves Safety Category 4, PL e per ISO 13849-1 and SIL 3 per IEC 61508. Achieving these levels requires that the monitoring system itself be rated appropriately and that the overall safety circuit architecture be validated by a qualified safety engineer.

Q: What diagnostic coverage does the RSe Series provide?

A: Monitoring both PNP proximity sensor outputs on each actuation and de-actuation provides a diagnostic coverage (DC) of 99%. This is the highest DC level recognized in the ISO 13849-1 framework and is a key contributor to achieving Category 4 PL e.

Q: What is a Safe Return Dual Pressure Application?

A: In a Safe Return Dual Pressure application, the RSe Series controls a double-acting cylinder using two different supply pressures. Port 3 supplies pressure to extend the cylinder (working stroke) and port 5 supplies a different pressure to retract the cylinder (return stroke). The RSe routing function ensures both pressures are controlled under redundant, monitored valve control, so the safe return position is always achieved on de-energization.

Q: What is a Safe Pressure Select Application?

A: A Safe Pressure Select application uses the RSe Series to select which of two available pressures is routed to a machine actuator or process. For example, a full-force pressure for production and a reduced pressure for setup mode. The RSe ensures this selection occurs only under redundant, safety-rated control with external position monitoring.

Q: What happens if one spool fails to shift during actuation?

A: If one spool shifts and the other does not, the proximity sensors will report discordant states to the external safety controller. The monitoring system must detect this discordance within the defined diagnostic time frame and inhibit further valve operation - typically by de-energizing both solenoids - until the fault is cleared and the system is reset.

Q: Does the RSe Series reset automatically after a fault?

A: The RSe valve itself resets automatically when both solenoids are de-energized - the spools return to their de-energized positions under spring force. However, the external safety monitoring system must detect and clear the fault condition before allowing the solenoids to be re-energized. The reset behavior of the overall safety system (automatic or manual) is determined by the external monitoring controller, not by the RSe valve itself.

Q: What are the available base sizes?

A: The RSe Series is available in 1/8 inch, 1/4 inch, and 1/2 inch base sizes with corresponding inlet, outlet, and exhaust port sizes. Flow coefficients range from 0.9 Cv for the 1/8 base up to 3.06 Cv for the 1/2 base.

Q: What voltage is available for the RSe Series?

A: All RSe Series valves operate at 24 VDC. Power consumption is 1.5 watts per solenoid. No AC voltage options are available.

Q: What certifications does the RSe Series carry?

A: The RSe Series carries CE certification, DGUV certification (German Social Accident Insurance, required for press safety in Germany), CSA/UL certification for North American markets, and an EAC Declaration for Eurasian markets. Safety performance is Category 4 PL e per ISO 13849-1 and SIL 3 per IEC 61508.

Q: Is a SISTEMA library available for the RSe Series?

A: Yes. ROSS Controls publishes a SISTEMA library file for the RSe Series that can be downloaded from rosscontrols.com. The library contains the required safety data (B10D, MTTFd, DC) for ISO 13849-1 PL verification calculations.

Installation & Maintenance Guidelines

• Mount the RSe Series valve on the correct base matching the port thread type (NPT or G) and base size. Captive mounting screws are provided; follow the specified torque values in the installation instructions.
• Plug all unused ports with the supplied port plugs. Unplugged ports will cause unintended pressure release or air supply contamination.
• Both solenoid connectors (EN 175301-803 Form C) must be wired to separate outputs of the external safety controller. Both solenoids must be energized simultaneously to produce valve output. Never wire both solenoids to the same output channel.
• Connect both M8 proximity sensor connectors to separate dual-channel inputs of the external safety monitoring controller. Monitor both sensor outputs on every actuation and de-actuation cycle.
• Program the external safety controller to detect discordance between the two proximity sensor signals. A predefined time window for discordance detection (typically based on valve response time plus a margin) must be established and validated.
• The external monitoring system must be capable of inhibiting valve re-energization upon detection of a fault condition. Verify this inhibit function operates correctly before placing the machine in service.
• Supply filtered air per ISO 8573-1 Class 7:4:4 maximum. Operating pressure must not exceed 145 psi (10 bar). Verify pilot supply is set within the required range.
• Pilot supply can be internal or external. For external pilot supply, ensure pilot pressure is equal to or greater than inlet pressure and within the specified operating range.
• After installation, perform a full functional test: actuate the valve and verify both proximity sensors confirm actuation; de-actuate and verify both sensors confirm de-actuation. Then simulate a single-spool failure and verify the monitoring system detects the fault and inhibits re-energization.
• Establish a documented proof test procedure and interval consistent with the PFD calculation for the safety function. Annual proof testing is a typical starting point.

Warranty & Global Support

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

Technical support for RSe Series installation, safety circuit integration, and external monitoring configuration is available from ROSS Controls USA at (800) 438-7677 or +1-248-764-1800.

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

For SISTEMA data, TUV certification documentation, dimensional drawings, and CAD models, visit the RSe Series product page at rosscontrols.com.

Download Catalog: https://www.rosscontrols.com/en/series/1300-rse-series-double-valve