CrossCheckTM CC4 Series Double Valves AWS
RC-CC4-OI 01.2018 EN
CROSSCHECKTM CC4 Series Safe Cylinder Stop and Load Holding Control Reliable Double Valves
Operating Instructions
Declaration of CE Conformity and Certifications available for download at www.rosscontrols.com
CROSSCHECK CC4 SERIES Operating Instructions PRODUCT KEY IDENTIFICATION
CC4
M
22
G
A
E
X
Dimensional Drawings
S
1/4 & 3/8
A
A
A
Series
Voltage 24 volts DC A
Pressure Release Manual M X Valve Only Basic Base Port Size Size Inlet Outlet 1/4 1/4 0 3/8 3/8 Valve Only (No Base) 1/2 1/2 2 3/4 3/4 Valve Only (No Base)
Communication None X
Thread BSPP G NPT N Valve Only X
DC
Pin Configuration Standard
F
D C
S B
Monitoring External E
22 23 2X 44 45 4X
E
F
E
Revision Level
1/2 & 3/4
B
IN
TPR
EPS 1/4 NPT
EXH
IN
TPR
EXH EPS 1/4 NPT
PRODUCT LABEL IDENTIFICATION
1/4 & 3/8
C ROSSC HECK ™ Safe Load Holding Valve
A
CC4M02NAEXSA CC4M0XXAEXSA
B
4
2
D
1
3
VALVE AND BASE:
VALVE LESS BASE: PRESSURE: 0 - 8 BAR 14 B 14 A
C
12 B 12 A
E
U.S. AND FOREIGN PATENTS PENDING
2
14B 14A
Simplified
12B 12A 1
12.37 (314.2) 5.72 (145.3) 4.10 (104.1) 4.60 (116.7) 5.11 (129.7)
13.01 (330.5) 6.84 (171.1) 5.20 (132.1) 5.80 (147.3) 4.87 (123.7)
3.41 (85.6)
3.55 (90.2)
F IN
SCHEMATICS 4
1/2 & 3/4 Dimension – Inches (mm)
EXH
Inlet Exhaust
EPS
External Pilot Supply
TPR
Trapped Pressure Release
3
Port Size
Flow Rates Pilot Valve 14 A
Pilot Valve 12 B
Ext Pi
CV
Basic
Inlet Outlet Exhaust Size
1-2 1-4 2-3 4-3
1/4
1/4
1/4
0
1
1
0.8 0.8
3/8
3/8
3/8
0
1
1
0.8 0.8
1/2
1/2
1/2
2
1.9
2
2
1.9
3/4
3/4
3/4
2
1.9
2
2
1.9
Trapped Pressure Release Valve
Valve Receptacle Pinout PORT 4 PORT 1
PORT 3
B
3 1
4
A
4 5
5
PORT 2 2
2
3
3
C
Valve Wiring Diagram
Pilot Valve 14 B
B
A
GRAY
4
5
2 WHITE
3
BLUE
BLUE
1 BROWN
2
5
4
3 BLUE
BLACK
4 BLACK
5 3
WHITE
14B 14A
Flow Control
2
WHITE
1
CC4 Series Cylinder Stop Load Holding Valve
C
1 GRAY
Application Example
Pressure Gauge
4
2 1
Pilot Valve 12 A
1 5
Trapped Pressure Release Valve
BLACK GRAY
4
1 3
2
Pressure Regulator Flow Control
BROWN BLUE
12B 12A
BROWN
BLUE BLUE
2
BROWN
+
SOL 12A
SOL 14A
+ -
+
SOL 14B
SOL 12B
+ -
BROWN
Filter
BLUE
L-O-X® Lockout Valve
POWER COMMON SENSOR A SENSOR B GROUND
BROWN BLUE WHITE BLACK GREEN
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Pneumatic Fluid Power - General Rules and Safety Requirements for Pneumatic Systems and their Components
- Safety related parts of a control system - Part 2 Safety of Machinery -Electrical equipment of machines - Part 1
Safety of Machinery - Safety related parts of a control system - Part 1 Safety of Machinery
Langen, July 28, 2017
Dietrich Warmbier Global Safety Product Manager
Signature
#ERTIÚCATION"ODYFOR4YPE4ESTING DGUV Test Prüf- und Zertifizierungsstelle Hebezeuge, Sicherheitskomponenten und Maschinen Fachbereich Holz und Metall Kreuzstraße 45 40210 Düsseldorf Tel.: 0211 8224-16910 Fax: 0211 8224 26910 [email protected] http://www.dguv.de/fb-holzundmetall/pruefstellen/hebezeuge Reference: HSM .OTIÚED"ODYWITHINTHE%UROPEAN5NION )$ .O #ERTIÚCATIONPENDING
Authorized person for the compilation of technical documentation: Klaus Goebel ROSS EUROPA GmbH Robert-Bosch-Strasse 2 63225 Langen / Germany
EN ISO 4414:2010-11:
EN60204-1:2006-06:
EN ISO 13849-2:2012:
EN ISO 13849-1:2015:
Applied harmonized standards:
are in full accordance with the following Directive: Machinery Directive 2006/42/EC
Herewith we declare that all ROSS® double valve CC4
(Translation from German-language Original)
Declaration of CE Conformity
Telefon: (06103) 7597- 0 • Fax: (06103) 74694 • e-mail: [email protected] • www.rosseuropa.com Sitz: Langen • AG: Langen, B412 • Geschäftsführer: Ralf W. Dinkel
ROSS EUROPA GmbH • Robert-Bosch-Strasse 2 • D-63225 Langen
Sicherheit von Maschinen -Elektrische Ausrüstung von Maschinen Teil 1 Fluidtechnik -Allgemeine Regeln und sicherheitstechnische Anforderungen an Pneumatikanlagen und deren Bauteile
EN60204-1:2006-06: EN ISO 4414:2010-11:
Langen, 28. Juli 2017
Dietrich Warmbier Global Safety Product Manager
Unterschrift
:ERTIÚZIERUNGSSTELLEDER"AUMUSTERPRÔFUNG DGUV Test Prüf- und Zertifizierungsstelle Hebezeuge, Sicherheitskomponenten und Maschinen Fachbereich Holz und Metall Kreuzstraße 45 40210 Düsseldorf Tel.: 0211 8224-16910 Fax: 0211 8224 26910 [email protected] http://www.dguv.de/fb-holzundmetall/pruefstellen/hebezeuge Kurzzeichen: HSM Benannte Stelle der EU, Kennnummer: 0393 :ERTIÚZIERUNGEINGELEITET
Bevollmächtigter für die Zusammenstellung der technischen Unterlagen: Klaus Goebel Fa. ROSS EUROPA Robert-Bosch-Straße 2 63225 Langen
EN ISO 13849-2:2012:
Sicherheit von Maschinen -Sicherheitsbezogene Teile von Steuerungen Teil 1 Sicherheit von Maschinen -Sicherheitsbezogene Teile von Steuerungen Teil 2
EN ISO 13849-1:2015:
Angewendete harmonisierte Normen:
den einschlägigen Bestimmungen folgender Richtlinien entsprechen: Maschinenrichtlinie 2006/42/EG
Hiermit erklären wir, dass alle ROSS®-Zwillingsventile der Baureihe CC4
(Originalfassung)
CE-Konformitätserklärung
Telefon: (06103) 7597- 0 • Fax: (06103) 74694 • e-mail: [email protected] • www.rosseuropa.com Sitz: Langen • AG: Langen, B412 • Geschäftsführer: Ralf W. Dinkel
ROSS EUROPA GmbH • Robert-Bosch-Strasse 2 • D-63225 Langen
CROSSCHECK CC4 SERIES Operating Instructions
3
CROSSCHECK CC4 SERIES Operating Instructions
1. About this Documentation
f 6. Notes on Safety
These instructions contain important information for the safe and appropriate assembly and commissioning of the product. f 5HDG WKHVH LQVWUXFWLRQV DOO WKH ZD\ WKURXJK SDUWLFXODUO\ VHFWLRQ} q6DIHW\ instructions,” before working with the product. Additional documentation: • 6,67(0$OLEUDULHV • '*89 IRUPHUO\%* FHUWLƂFDWH *HUPDQSURIHVVLRQDODVVRFLDWLRQ • Technical documents For more information see last page for contact information, or visit www.rosscontrols.com. f ,Q DGGLWLRQ REVHUYH DOO DSSOLFDEOH ORFDO DQG QDWLRQDO UHJXODWLRQV RQ DFFLGHQW prevention and on environmental protection.
The product has been manufactured according to the accepted rules of current technology. There is risk of injury or damage if the following safety instructions and warnings given in this instruction manual are not observed.
6.1. Intended Use
Product label identification & product key identification example, see page 2.
The CROSSCHECKTM && 6HULHV GRXEOH YDOYHV DUH VDIHW\ FRPSRQHQWV GHVLJQHG DQG PDQXIDFWXUHGLQDFFRUGDQFHZLWK0DFKLQHU\'LUHFWLYH(&DQGEHDUWKH&( mark. The CROSSCHECKTM OLQH RI GRXEOH YDOYHV DUH UHGXQGDQW SRUWHG SRVLWLRQ FORVHGFHQWHU SQHXPDWLF YDOYHV WKDW DUH GHVLJQHG WR PHHW WKH QHHGV DQG UHTXLUHPHQWV RI VDIH F\OLQGHU VWRS DQG ORDGKROGLQJ DSSOLFDWLRQV IRU PDFKLQHU\ ZLWK SQHXPDWLFFRQWUROV7\SLFDOO\WKHVHYDOYHVDUHLPSOHPHQWHGWRPHHWWKH&DWHJRU\ and/or Performance Level e requirements of a machine’s (or system’s) safety circuit DVGHWHUPLQHGE\DULVNDVVHVVPHQWRIWKHKD]DUGVDQGWDVNVUHTXLUHGRIHPSOR\HHV WKDWLQWHUDFWZLWKWKHPDFKLQH V\VWHP 7KHYDOYHLVFRQVWUXFWHGZLWKWLJKWVHDOLQJ GLUWWROHUDQWSRSSHWW\SHLQWHUQDOV7KHYDOYHDOVRKDVDQLQWHJUDWHGWUDSSHGSUHVVXUH release system. After stopping a cylinder and performing lockout/tagout, trapped SUHVVXUHFDQEHUHOHDVHGE\ZD\RIPDQXDOO\RSHUDWHGZD\YDOYHVORFDWHGDWHDFK HQGRIWKHYDOYHpVVXEEDVHtRQHHDFKSHUYDOYHRXWOHWSRUW f 6HHVHFWLRQq7HFKQLFDO'DWDrIRUWKHVWDQGDUGVDQGWHVWYDOXHVFRPSOLHGZLWK DQG DGKHUHG WR E\ WKH SURGXFW 6HH WKH GHFODUDWLRQ RI FRPIRUPLW\ IRU SURGXFW UHOHYDQW(&GLUHFWLYHV The CROSSCHECKTM &&6HULHVYDOYHLVGHVLJQHGWRFRQWUROWKHGLUHFWLRQRIDLUƃRZLQWR DQGRXWRIDGRXEOHDFWLQJF\OLQGHURURWKHUSQHXPDWLFDFWXDWRULQRUGHUWRGULYHWKH cylinder forward or backward to suit the requirements of the machine operation until signaled to shut off and trap pneumatic energy in the cylinder in order to stop cylinder PRWLRQ ORDG KROGLQJ 7KXV UHGXFLQJ WKH SRWHQWLDO KD]DUG RI XQH[SHFWHG F\OLQGHU PRWLRQGXULQJHPSOR\HHDFFHVVIRUSURGXFWLRQUHODWHGWDVNVDQGRUPLQRUVHUYLFLQJ 7XUQLQJRIIDOOVROHQRLGVRQWKHCROSSCHECKTM &&6HULHVYDOYHUHWXUQVWKHYDOYH WRWKHFHQWHUSRVLWLRQLQRUGHUWRVWRSWKHF\OLQGHUPRWLRQWKLVDOVRDOORZVMRJJLQJRI the cylinder. However, the CROSSCHECKTM&&6HULHVYDOYHRIIHUVWKLVIXQFWLRQZLWKWKH required level of control expected of the machine’s (system’s} safety control system XSWR&DWHJRU\3/H6XFKDFRQWUROV\VWHPPXVWEHFDSDEOHRILQKLELWLQJIXUWKHU operation of the valve in the event of a fault within the valve. The safety function of the CROSSCHECKTM &&6HULHVYDOYHLVWREORFNIXUWKHUVXSSO\RI pneumatic energy through the valve and also to block the exhaust of any pneumatic energy from the cylinder lines and cylinder downstream of the valve whenever the YDOYHLVVKXWRIIRUDIDXOWRFFXUVZLWKLQWKHYDOYH 6HHVHFWLRQ 127( 7KHCROSSCHECKTM&&6HULHVYDOYHFDQQRWSUHYHQWORVVRISQHXPDWLFHQHUJ\ (compressed air) from downstream of the valve that may occur through leaks in pipe RU WXEH ƂWWLQJV EURNHQ SLSLQJ RU WXELQJ F\OLQGHU URG VHDOV F\OLQGHU SLVWRQ VHDOV RU other control valves. The CROSSCHECKTM && 6HULHV YDOYHV DUH GHVLJQHG IRU H[WHUQDO PRQLWRULQJ IRU safe, redundant operation of the valves. The CROSSCHECKTM && 6HULHV YDOYHV DUH constructed of redundant, poppet type valves, and have an overall function of a double VROHQRLGSLORWRSHUDWHGVSULQJFHQWHUHGYDOYH(DFKVLQJOHYDOYHLQWKHCROSSCHECKTM CC4 SHULHV LV HTXLSSHG ZLWK D +DOOHIIHFW PLGSRVLWLRQ VHQVRU 0RQLWRULQJ ERWK RI WKHVHVHQVRUVRQHDFKDFWXDWLRQDQGGHDFWXDWLRQRIWKHCROSSCHECKTM&&6HULHV YDOYHSURYLGHVDGLDJQRVWLFFRYHUDJHXSWR 0RQLWRULQJRIWKHVHVHQVRUVPXVWEH SHUIRUPHGE\DQH[WHUQDOPRQLWRULQJV\VWHP6XFKDPRQLWRULQJV\VWHPLVEHFDSDEOH RI LQKLELWLQJ WKH RSHUDWLRQ RI WKH YDOYH7KH VDIHW\ FRQWURO V\VWHP PXVW GHHQHUJL]H the valve’s solenoids in the event of a fault within the valve and/or within the safety control system and check for achievement of the center position before allowing an DWWHPSWWRUHHQHUJL]HWKHYDOYH:KHQDIDXOWRFFXUVYDOYHUHVHWLVDFFRPSOLVKHGE\ GHHQHUJL]LQJDOORIWKHYDOYHpVVROHQRLGV
3. Prerequisites for Use of the Product
6.1.1. Safety Function According to ISO 13849 and EN 692
f 0DNH WKHVH RSHUDWLQJ LQVWUXFWLRQV DYDLODEOH WR WKH HQJLQHHU DQG DVVHPEO\ technician of the machine/system in which the product will be used. f Keep these operating instructions for the entire product life cycle.
CROSSCHECKTM&&6HULHVYDOYHVDUHGHVLJQHGLQDFFRUGDQFHZLWKWKHUHTXLUHPHQWV OLVWHG LQ ,62 DQG 7KHLUqIDLOWRVDIHr VDIHW\ IXQFWLRQ LV HQVXUHG HYHQ LQ case of a single fault within the valve (e.g., caused by wear, contamination, or similar situations). The safety function of the CROSSCHECKTM&&6HULHVYDOYHLVWREORFNDOOWKHYDOYHpV ports in order to stop motion of the cylinder it is controlling (load holding). The valve can only drive the cylinder it is controlling forward or backward when the two internal YDOYHHOHPHQWVDUHVXFFHVVIXOO\DFWXDWHGVLPXOWDQHRXVO\ HLWKHUVROHQRLGV$ % RU$ % 2WKHUZLVHWKHCROSSCHECKTM&&6HULHVYDOYHZLOOVKXWRIIDOOSRUWV when the valve is shut off or if only one of the two internal valve elements is actuated. A fault in the system where only one valve actuates when switching on or only one GHDFWXDWHV ZKHQ VZLWFKLQJ RII SUHYHQWV DLU IURP EHLQJ VXSSOLHG GRZQVWUHDP DQG simultaneously blocks the exhaust of any air that is already downstream in the cylinder OLQHVDQGF\OLQGHU0RQLWRULQJRIWKHWZR+DOOHIIHFWPLGSRVLWLRQVHQVRUVE\WKHXVHUpV external safety monitoring system makes it possible to detect these fault situations and WRVKXWRIIDQGSUHYHQWIXUWKHUHOHFWULFDOHQHUJL]DWLRQRIWKHVROHQRLGV The control outputs of the safety system must be designed and constructed to meet the Category and/or Performance Level requirements of the safety system, as determined E\WKHULVNDVVHVVPHQWRIWKHPDFKLQH1RUPDOO\WKHRXWSXWWRWKHVROHQRLGVLVDGXDO channel output from a safety relay or safety PLC.
1.1. Warning Notices in these Operating Instructions ,Q WKHVH RSHUDWLQJ LQVWUXFWLRQV ZDUQLQJ QRWLFHV SUHFHGH VHFWLRQV ZLWK KDQGOLQJ requirements which incur risks of personal injury or material damage. Warnings are structured as follows:
SIGNAL WORD Type or source of hazard! Consequences f Measures to avert danger • • • • •
Warning triangle:,QGLFDWHVDULVNRIIDWDORUVHYHUHLQMXULHV Signal word: ,QGLFDWHVWKHVHYHULW\RIWKHGDQJHU Type or source of hazard:6WDWHVWKHW\SHRIGDQJHURUWKHVRXUFHRIWKHKD]DUG Consequences: Describes possible consequences of ignoring the warning. Measures to avert danger:},QGLFDWHVKRZWRDYRLGWKHGDQJHU,WLVHVVHQWLDOWKDW the measures to avert danger are complied with.
DANGER
Indicates an imminent and serious danger that will result in severe or even fatal injury if you fail to avoid it.
WARNING
Indicates a possible danger that could result in severe or even fatal injury if you fail to avoid it.
CAUTION
ATTENTION
Indicates a danger that may result in minor to moderate injuries if you fail to avoid it. Indicates potential property damage that may be incurred by the product or its surroundings if you fail to avoid it.
2. Product Identification Date of manufacture and site of manufacture are permanently stamped:
Manufacturing site
Site abbreviation
(L) ROSS CONTROLS USA (G) ROSS EUROPA (RB) ROSS UK (J) ROSS ASIA (B) ROSS SOUTH AMERICA (C) ROSS CONTROLS CHINA (RCI) ROSS CONTROLS INDIA See back page for ROSS addresses.
Valve printing (example May 2016) (5 16 L) (5 16 G) (5 16 RB) (5 16 J) (5 16 B) (5 16 C) (5 16 RCI)
3.1. Qualified Personnel Assembly, installation, commissioning, maintenance, and decommissioning should RQO\ EH FDUULHG RXW E\ TXDOLƂHG SHUVRQQHO WKDW KDYH WKH UHTXLUHG NQRZOHGJH RI DQG experience in dealing with electrical and pneumatic control technology.
4. Package Contents ,WHPVLQFOXGHG • CROSSCHECKTM&&6HULHVYDOYH • Operating instructions
5. Service, Repair, and Maintenance f ,QFDVHRIWHFKQLFDOSUREOHPVRUDUHTXLUHGUHSDLUSOHDVHFRQWDFW\RXUORFDO5266 UHSUHVHQWDWLYH ,I XVHG SURSHUO\ WKH CROSSCHECKTM CC4 6HULHV YDOYHV ZLOO QRW UHTXLUHPDLQWHQDQFH8QOHVVRWKHUZLVHUHTXLUHG5266® recommends performing a functional test at least annually (see 8.1 Test Procedure).
4
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CROSSCHECK CC4 SERIES Operating Instructions 6.1.2. Common Cause Failure – CCF The product has been engineered and manufactured according to the fundamental and SURYHQVDIHW\SULQFLSOHVRI,62 DQG Common Cause Failures (CCF) are failures of different components, resulting from a single event. CCF are not to be confused with cascading faults or common mode faults. Common cause failures can cause loss of the safety function, especially in dual channel circuits where both channels could fail simultaneously due to a single event. s 0DLQWDLQFRPSUHVVHGDLUTXDOLW\LHƂOWUDWLRQSUHVVXUHUHJXODWLRQOXEULFDWLRQ • Avoid compressor oils that can cause valve seals to swell, soften, or otherwise deteriorate. • Operate within prescribed temperature limits. s ,QVWDOO WKH YDOYH VXFK WKDW WKH QRUPDO VWURNH WUDYHO RI WKH YDOYH HOHPHQWV DUH perpendicular to the main direction of machine vibration and/or mechanical shock. s 'RQRWXVHDWHVWSXOVHORQJHUWKDQDOORZHGE\WKH7HFKQLFDO6SHFLƂFDWLRQV s $YRLGH[WHUQDOPDJQHWLFƂHOGV • Do not plug the valve exhaust port. • 8VHRQO\KLJKƃRZQRQFORJJLQJVLOHQFHUVZLWKVLPLODURUKLJKHUVSHFLƂFDWLRQVDV 5266® silencers.
6.1.3. Diagnostic Coverage $ GLDJQRVWLF FRYHUDJH RI LV DFKLHYDEOH WKURXJK DSSURSULDWH LQWHJUDWLRQ RI WKH CROSSCHECKTM&&6HULHVYDOYHLQWRWKHVDIHW\FRQWUROV\VWHP7KHPRQLWRULQJV\VWHP PXVWFKHFNIRUWKHSURSHUFKDQJHRIVWDWHRIHDFKYDOYHVHQVRU 6HQVRU$ 6HQVRU% with each change of state of the safety control system outputs to the valve solenoids 6ROHQRLGV $ % RU 6ROHQRLGV $ % 'HWHFWLRQ RI D IDXOW E\ WKH VDIHW\ FRQWURO V\VWHP PXVW WULJJHU D VKXWRII RI WKH VDIHW\ FRQWUROOHUpV RXWSXWV WR DOO RI WKH YDOYHpVVROHQRLGV $%$ % VHHVHFWLRQ
6.1.4. Fault Modes 1RWH WKDW QRUPDO RSHUDWLRQ UHTXLUHV WKDW VROHQRLGV $ % EH HQHUJL]HG simultaneously for switching the CROSSCHECKTM&&6HULHVYDOYHRQLQRUGHUWRGULYHWKH F\OLQGHUIRUZDUG SRUWSUHVVXUL]HGDQGSRUWH[KDXVWHG RUWKDWVROHQRLGV$ % EHHQHUJL]HGVLPXOWDQHRXVO\LQRUGHUWRGULYHWKHF\OLQGHUEDFNZDUG SRUWSUHVVXUL]HG DQG SRUW H[KDXVWHG 'HHQHUJL]LQJ DOO RI WKH YDOYHpV VROHQRLGV VLPXOWDQHRXVO\ switches the CROSSCHECKTM&&6HULHVYDOYHRIIDQGWUDSVSUHVVXUHRQSRUWV LQ RUGHUWRVWRSWKHF\OLQGHU ORDGKROGLQJ Faults that could occur during normal operation: 6ROHQRLGV$ %HQHUJL]HGVLPXOWDQHRXVO\ 62162)) 62))621 621621 6ROHQRLGV$ %HQHUJL]HGVLPXOWDQHRXVO\ 62162)) 62))621 621621 $OOVROHQRLGVGHHQHUJL]HGVLPXOWDQHRXVO\ 62162II 62))621 62))62))
WARNING Risk of Injury! Misuse may result in injury or damage. f The product must be used exclusively as intended. Foreseeable misuse includes: • Use outdoors • Bypassing the safety function or diagnostics s )DLOLQJ WR XWLOL]H WKH RQERDUG PLGSRVLWLRQ VHQVRUV WR YHULI\ YDOYH RSHUDWLRQ RQ HYHU\F\FOHtHQHUJL]LQJDQGGHHQHUJL]LQJ • Allowing continued operation of the valve when one or both valve shifted signals IURPWKHRQERDUGPLGSRVLWLRQVHQVRUV DUHQRWFRQƂUPHG • Use in reverse operation (reversal of supply and exhaust air) s 2SHUDWLRQLQORZGHPDQGPRGHSHU,(& • Operating at pressures below minimum operating pressure or above maximum operating pressure.
6.2. Responsibilities of the System Owner
s s
Observe the information on assembly and operating conditions listed in the operating instructions or the data sheet. &RPSO\ZLWKWKHIXUWKHUUHTXLUHPHQWVRI,62 HJ&&)'&3/UVRIWZDUH LI\RXLQWHQGWRXVHWKHSURGXFWLQKLJKHUFDWHJRULHV RU 0DNHVXUHWKDWWKHPD[LPXPQXPEHURIVZLWFKLQJF\FOHV %') within the service life TmLVQRWH[FHHGHG,IWKHH[SHFWHGQXPEHURIVZLWFKLQJF\FOHVIRUDFRPSRQHQW exceeds the B' value during its period of use, suitable replacement intervals have WREHVSHFLƂHG
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6ZLWFKWKHYDOYHDWOHDVWRQFHDPRQWK to ensure its proper operation. 0DNHVXUHWKDWWKHIXQGDPHQWDODQGSURYHQVDIHW\SULQFLSOHVLQDFFRUGDQFHZLWK ,62 IRULPSOHPHQWDWLRQDQGRSHUDWLRQRIWKHFRPSRQHQWDUHFRPSOLHGZLWK 0DNHVXUHWKDWWKHSHUPLVVLEOHVZLWFKRQDQGVZLWFKRIISXOVHVIRUIHHGEDFNIUHH operation of the pneumatic devices are observed. ,I\RXRSHUDWHWKHCROSSCHECKTM&&6HULHVYDOYHWRJHWKHUZLWKDQHOHFWULFWZR KDQGFRQWUROLWPXVWFRPSO\ZLWKWKH(1VWDQGDUG6HOHFWLRQDQGLQVWDOODWLRQ RI WKLV WZRKDQG FRQWURO PXVW WDNH SODFH LQ DFFRUGDQFH ZLWK WKH PDQXIDFWXUHUpV VSHFLƂFDWLRQV
6.3. Safety Instructions •
s s s s
When implementing surge suppression measures, be sure to check whether or not this extends the valve shut off response time which could extend the machine stopping time. ,Q FDVH RI KLJK OHYHOV RI PDFKLQH YLEUDWLRQ XVH DSSURSULDWH YLEUDWLRQUHGXFLQJ elements when installing the valve. 6XSSO\WKHSURSHUYROWDJHDVRYHUYROWDJHVLWXDWLRQVFDQUHVXOWLQVROHQRLGEXUQRXW 0DNH VXUH WKDW WKH VLOHQFHUpV ƃRZ FDSDFLW\ LV QRW UHVWULFWHG DV WKLV FRXOG DIIHFW system performance. ,IUHTXLUHGUHSODFHWKHVLOHQFHUH[FOXVLYHO\ZLWKDFRUUHVSRQGLQJ5266PRGHO
7. Assembly and Installation CAUTIONS Risk of injury due to installation while pressurized or with live parts! ,QVWDOODWLRQ ZKLOH SUHVVXUL]HG RU ZLWK HOHFWULFDO SRZHU VZLWFKHG RQ FDQ UHVXOW LQ LQMXULHVGXHWRVXGGHQSUHVVXUHEXLOGXSRUHOHFWULFVKRFN f 'HHQHUJL]HDQGGHSUHVVXUL]HWKHUHOHYDQWV\VWHPSDUWVEHIRUHLQVWDOOLQJWKH valves. f 6HFXUHWKHV\VWHPWRSUHYHQWLWEHLQJVZLWFKHGEDFNRQDJDLQ
ATTENTION Destruction of components! Chemical substances can damage the surface, the markings and the seals of the device. f ,QVWDOOWKHYDOYHVXFKWKDWLWLVSURWHFWHGDJDLQVWWKHHIIHFWVRIFKHPLFDOV Damage to the device through storage at incorrect temperatures! The storage temperature represents the permissible ambient temperature and depends on the type of valve in question. f 2EVHUYHWKHWHPSHUDWXUHLQIRUPDWLRQLQFKDSWHUq7HFKQLFDO'DWDr
7.1. Mechanical Installation 6HFXUHWKHYDOYHXVLQJWKHWKURXJKKROHVLQWKHYDOYHEDVH5HIHUWRSDWWHUQIRUWKH UHTXLUHGGLPHQVLRQVVHHGLPHQVLRQDOGUDZLQJVRQSDJH
7.2. Pneumatic Installation &RQQHFWWKHFRPSUHVVHGDLUVXSSO\WRSRUW&RQQHFWSRUWDQGSRUWWRWKH downstream portion of the circuit.
6.1.5. Foreseeable Misuse
•
s s
7.3. Pneumatic and Electrical Connections (OHFWULFDO FRQQHFWLRQV WR WKH VROHQRLGV DQG VHQVRUV DUH PDGH ZLWK PDOH SLQ 0 UHFHSWDFOHV RQ WKH YDOYH 6HH 3LQRXWV RQ SDJH )HPDOH FRQQHFWRUV DQG FDEOHV aresold separately. The cables and cable connections as well as the electrical control for the double valves must comply with the applicable safety regulations.
8. Commissioning and Operation CAUTIONS Damage to health due to loud noise! Levels above 70 dB(A) may lead to damage to health! f Always wear ear protectors when working on the product. %HIRUH FRPPLVVLRQLQJ WKH LQVWDOODWLRQ KDV WR EH FDUHIXOO\ LQVSHFWHG E\ D TXDOLƂHG trained professional. 0DNH VXUH WKDW WKH WHFKQLFDO VSHFLƂFDWLRQV PDWFKHV WKH RSHUDWLQJ FULWHULD RI WKH machine and/or the pneumatic system. Always set the compressed air supply to a level that ensures that the minimum RSHUDWLQJSUHVVXUHLVDGKHUHGWR VHHVHFWLRQ7HFKQLFDO6SHFLƂFDWLRQV
8.1. Test Procedure 8VH WKLV WHVW SURFHGXUH WR FRQƂUP YDOYH DQG VHQVRU IXQFWLRQ 7KH WHVW SURFHGXUH EHORZ DVVXPHV DOO SUHVVXUH LV UHPRYHG IURP WKH V\VWHP DQG DOO VROHQRLGV DUH GH HQHUJL]HGSULRUWREHJLQQLQJWKHSURFHGXUH
5
CROSSCHECK CC4 SERIES Operating Instructions
Design:5HGXQGDQW&ORVHG&HQWHUVSULQJFHQWHUHGGLUHFWLRQDOYDOYHHOHPHQWVRI poppet construction. Mounting Type: 6XEEDVHPRXQWHG Actuation: 6ROHQRLGSLORWRSHUDWHGZLWKVSULQJUHWXUQWRFHQWHU7ZRVROHQRLGVSHUYDOYH HOHPHQWtIRXUWRWDO(QHUJL]HVROHQRLGV$DQG%WRSUHVVXUL]HSRUWDQGH[KDXVW SRUW(QHUJL]HVROHQRLGV$DQG%WRSUHVVXUL]HSRUWDQGH[KDXVWSRUW Mounting Type: 6XEEDVHPRXQWHG Pilot Solenoid:9HUVLRQDVSHU9'(5DWHGIRUFRQWLQXRXVGXW\ (OHFWULFDOFRQQHFWLRQDFFRUGLQJWR(1)RUP&(QFORVXUHUDWLQJDFFRUG LQJWR',1,3 Standard Voltages: YROWV'& Pilot Solenoids Power Consumption:ZDWWVSHUVROHQRLG tRQO\RIZKLFK VKRXOGEHHQHUJL]HGDWRQHWLPH Electrical Connections: Three SLQ0FRQQHFWRUV Mid-Position Sensors:SHUYDOYH+DOOHIIHFWGLVFUHHW P$ Ambient Temperature: WR) &WR& Medium Temperature:WR) &WR& )RUWHPSHUDWXUHVEHORZ& ) WKHFRPSUHVVHGDLUPXVWEHGULHGDFFRUGLQJWR ,62FODVV Flow Media: &RPSUHVVHGDLU LQHUWJDVHV ƂOWHUHGLQDFFZLWK,62 FODVV P ZLWKRUZLWKRXWLQOLQHOXEULFDWLRQ PLQHUDORLOVDFFRUGLQJWR,62 ,629*YLVFRVLW\FODVV Inlet Pressure: With Internal Pilot Supply:WRSVLJ WREDU With External Pilot Supply:WRSVLJ WREDU Pilot Supply Pressure: WRSVLJ WREDU 0XVWEHHTXDOWRRUJUHDWHUWKDQ inlet pressure. Static Pressure: WRSVLJ WREDU Mounting Orientation:$Q\EXWKRUL]RQWDOO\ZLWKVROHQRLGVRQWRSLVSUHIHUUHG Monitoring: Dynamic, cyclical, external with customer supplied equipment. 0RQLWRULQJVKRXOGFKHFNVWDWHRIERWKYDOYHPLGSRVLWLRQVHQVRUVZLWKDQ\DQGDOO changes in state of valve control signals. Shock Test (based on DIN EN 60068-2-27): s $FFHOHUDWLRQ &RQVXOW5266 s 6KRFNGXUDWLRQ &RQVXOW5266 s 6KRFNZDYHIRUP &RQVXOW5266 s 9LEUDWLRQWHVW EDVHGRQ',1(1 s )UHTXHQF\ &RQVXOW5266 s $PSOLWXGH &RQVXOW5266 B10D Value according to ISO 13849-1 and -2:6HUYLFHOLIHSDUDPHWHUPHDVXUHG DFFRUGLQJWR5266(QJLQHHULQJ6WDQGDUG/DERUDWRU\7HVW3URFHGXUHV6HFWLRQ 6L]H %' PLOOLRQF\FOHV 6L]H %' &RQVXOW5266 Mid-position Sensors: T' &RQVXOW5266 Maximum Cycle Rate: &RQVXOW5266+]PHDVXUHGZLWKRXWYROXPH7KHVZLWFKLQJ frequency decreases depending on the volume to be controlled. Sound Pressure Level [dB(A)]:&RQVXOW52667KHVRXQGSUHVVXUHOHYHOis LQƃXHQFHGE\WKHLQGLYLGXDOV\VWHPVXVHGIRUUHGXFWLRQRIQRLVHHPLVVLRQV8VH RQO\VLOHQFHUVZLWKH[KDXVWƃRZFDSDELOLW\JUHDWHUWKDQWKHH[KDXVWFDSDELOLW\RIWKH valve, do not restrict the valve exhaust. Use of the product without the silencer is not recommended. Minimum Operation Frequency: Once a month, to ensure proper function operation.
Momentarily energize solenoids 12A & 12B
Energize solenoid 12A De-energize solenoid 12A Energize solenoid 12B De-energize solenoid 12B Energize solenoid 14A De-energize solenoid 14A Energize solenoid 14B De-energize solenoid 14B 13 14 15 16 17 18 19 20
9
10 11
8
12
Line Line
Line Line
0 0 On Off
On On
On Off Off Off
Off Off
Off Off
0 Line Off Off On On
Line Line Off Off On On 7
Step Fault Conditions Precedures Acctions #
If not already retracted.
None None Retract Stays put Extend Stays put Partial retract Retract Partial extend Extend None Off On Off On Off On Off then On Off Off then On Off On Off On Off On Off On Off then On Off Off then On Off On 0 0 0 0 Line Line 0 0 Line Line 0 0 Off Off Off Off On Off Off Off Off Off On Off Off Off On Off Off Off Off Off On Off Off Off
Supply pressure to port 1 Apply power to the valve position sensors Energize solenoids 12A & 12B De-energize solenoids 12A & 12B Energize solenoids 14A & 14B De-energize solenoids 14A & 14B Momentarily energize solenoids 12A & 12B Energize solenoids 12A & 12B Momentarily energize solenoids 14A & 14B Energize solenoids 14A & 14B De-energize solenoids 14A & 14B 1 2 3 4 5 6
Step #
Normal Valve & Sensor Function Precedures Acctions
Sol 12A
Sol 12B
Sol 14A
Sol 14B
Outlet pressure Port 2 Port 4
Cylinder Sensor condition Notes Sensor A Sensor B Action
.
Sol Sol Sol Sol Outlet pressure Sensor condition Cylinder Notes 12A 12B 14A 14B Port 2 Port 4 Sensor A Sensor B Action On On Off then Off then Partial Energize only long enough Line Line then then Off Off On On retract for a partial stroke. off off On Off Off Off Line Line Off On None Fault Off Off Off Off Line Line On On None No fault Off On Off Off Line Line On Off None Fault Off Off Off Off Line Line On On None No fault Off Off On Off Line Line Off On None Fault Off Off Off Off Line Line On On None No fault Off Off Off On Line Line On Off None Fault Off Off Off Off Line Line On On None No fault
10. Technical Specifications
6WHSVtDUHWRFRQƂUPYDOYHDQGVHQVRUIXQFWLRQGXULQJIDXOWFRQGLWLRQV Energize only long enough for a partial stroke. Finish the stroke Energize only long enough for a partial stroke. Finish the stroke.
6WHSVtDUHWRFRQƂUPQRUPDOYDOYHDQGVHQVRUIXQFWLRQ
Results from the test procedure other than those listed above could indicated a valve PDOIXQFWLRQ6HHVHFWLRQ6HUYLFH5HSDLUDQG0DLQWHQDQFH Failure of the internal valve elements to shift synchronously leads to a fault in the CROSSCHECKTM&&6HULHVYDOYH7KLVFRXOGKDSSHQIRUDYDULHW\RIUHDVRQVVXFKDV • Defective piston seals, s 0DLQYDOYHHOHPHQWVH[SHULHQFLQJDVZLWFKLQJGHOD\GXHWRGLUWRUUHVLQRXVRLO s ,QVXIƂFLHQWHOHFWULFDOVLJQDOVWRYDOYHVROHQRLGV VXLWDEOHYROWDJHQRWDYDLODEOH • Receipt of signals at solenoids not synchronous, • Pilot valves experiencing a switching delay due to damaged components, dirt, or resinous oil, s ([FHVVLYHZDWHUEXLOGXSLQWKHYDOYH
11. Disposal Dispose of the valve in accordance with the applicable statutory regulations in your country.
9. Disconnecting and Removal CAUTIONS Risk of injury due to disconnecting pressurized or live parts. f 'LVFRQQHFWLQJDSQHXPDWLFFRPSRQHQWZKLOHWKHV\VWHPLVSUHVVXUL]HG or while electrical power is supplied can result in injury or death due to sudden pressure release, unexpected movement, or electric shock. f ,VRODWHDQGORFNRXWWKHHOHFWULFDODQGSQHXPDWLFV\VWHPVEHIRUH disconnecting the valves.
6
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CROSSCHECK CC4 SERIES Operating Instructions
CAUTIONS And WARNINGS PRE-INSTALLATION or SERVICE 1. Before servicing a valve or other pneumatic component, be sure that all sources of energy are turned off, the entire pneumatic system is shut off and exhausted, and all power sources are locked out (ref: OSHA 1910.147, EN 1037). 2. All ROSS products, including service kits and parts, should be installed and/or serviced only by persons having training and experience with pneumatic equipment. Because any installation can be tampered with or need servicing after installation, persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance. 3. All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment. In addition, overhauled or serviced valves must be functionally tested prior to installation and use. If you have any questions, call your nearest ROSS location listed on the cover of this document. 4. Each ROSS product should be used within its specification limits. In addition, use only ROSS parts to repair ROSS products. WARNING: Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury or damage to property. FILTRATION and LUBRICATION 5. Dirt, scale, moisture, etc. are present in virtually every air system. Although some valves are more tolerant of these contaminants than others, best performance will be realized if a filter is installed to clean the air supply, thus preventing contaminants from interfering with the proper performance of the equipment. ROSS recommends a filter with a 5-micron rating for normal applications. 6. All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only. Do not fail to use the metal bowl guard, where provided, to minimize danger from high pressure fragmentation in the event of bowl failure. Do not expose these products to certain fluids, such as alcohol or liquefied petroleum gas, as they can cause bowls to rupture, creating a combustible condition, hazardous leakage, and the potential for human injury or damage to property. Immediately replace a crazed, cracked, or deteriorated bowl. When bowl gets dirty, replace it or wipe it with a clean dry cloth. 7. Only use lubricants which are compatible with materials used in the valves and other components in the system. Normally, compatible lubricants are petroleum based oils with oxidation inhibitors, an aniline point between 180°F (82°C) and 220°F (104°C), and an ISO 32, or lighter, viscosity. Avoid oils with phosphate type additives which can harm polyurethane components, potentially leading to valve failure which risks human injury, and/or damage to property. AVOID INTAKE/EXHAUST RESTRICTION 8. Do not restrict the air flow in the supply line. To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action. 9. Do not restrict a valve’s exhaust port as this can adversely affect its operation. Exhaust silencers must be resistant to clogging and must have flow capacities at least as great as the exhaust capacities of the valves. Contamination of the silencer can result in reduced flow and increased back pressure. WARNING: ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type, wrong size, or an inadequately maintained silencer installed with a ROSS product. POWER PRESSES 10. Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device. A double valve without a self-contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve. All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism. ENERGY ISOLATION/EMERGENCY STOP 11. Per specifications and regulations, ROSS L-O-X® and L-O-X® with EEZ-ON® operation products are defined as energy isolation devices, NOT AS EMERGENCY STOP DEVICES.
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7
ROSS CONTROLS
U.S.A. Tel: +1-248-764-1800 Customer Svs. 1-800-GET-ROSS (438-7677) Technical Svs. 1-888-TEK-ROSS (835-7677) [email protected] www.rosscontrols.com
ROSS EUROPA GmbH Germany Tel: +49-6103-7597-0 [email protected] www.rosseuropa.com
ROSS ASIA K.K.
Japan Tel: +81-42-778-7251 www.rossasia.co.jp
ROSS UK Ltd.
United Kingdom Tel: +44-1543-671495 [email protected] www.rossuk.co.uk
ROSS CONTROLS INDIA Pvt. Ltd. India Tel: +91-44-2624-9040 [email protected]
ROSS SOUTH AMERICA Ltda. Brazil Tel: +55-11-4335-2200 [email protected] www.rosscontrols.com.br
ROSS FRANCE SAS
France Tel: +33-1-49-45-65-65 www.rossfrance.com
ROSS CONTROLS (CHINA) Ltd. China Tel: +86-21-6915-7961 [email protected] www.rosscontrolschina.com
ROSS CANADA
Canada Tel: +1-416-251-7677 [email protected] www.rosscanada.com 6077170 CANADA INC. AN INDEPENDENT REPRESENTATIVE
Printed in the U.S.A. – Rev. 01/11/18 © 2018 ROSS CONTROLS®. All Rights Reserved. Content subject to change. Form RC-CC4-OI
STANDARD WARRANTY All products sold by ROSS CONTROLS are warranted for a one-year period [with the exception of all Filters, Regulators and Lubricators (“FRLs”) which are warranted for a period of seven years] from the date of purchase to be free of defects in material and workmanship. ROSS’ obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective. This warranty becomes void in the event that product has been subject to misuse, misapplication, improper maintenance, modification or tampering. THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND/OR HEALTH LAWS OR REGULATIONS. IN NO EVENT IS ROSS LIABLE TO PURCHASER, USER, THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS. NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS MAY EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN.
CROSSCHECKTM CC4 Series Safe Cylinder Stop and Load Holding Control Reliable Double Valves
Operating Instructions
Declaration of CE Conformity and Certifications available for download at www.rosscontrols.com
CROSSCHECK CC4 SERIES Operating Instructions PRODUCT KEY IDENTIFICATION
CC4
M
22
G
A
E
X
Dimensional Drawings
S
1/4 & 3/8
A
A
A
Series
Voltage 24 volts DC A
Pressure Release Manual M X Valve Only Basic Base Port Size Size Inlet Outlet 1/4 1/4 0 3/8 3/8 Valve Only (No Base) 1/2 1/2 2 3/4 3/4 Valve Only (No Base)
Communication None X
Thread BSPP G NPT N Valve Only X
DC
Pin Configuration Standard
F
D C
S B
Monitoring External E
22 23 2X 44 45 4X
E
F
E
Revision Level
1/2 & 3/4
B
IN
TPR
EPS 1/4 NPT
EXH
IN
TPR
EXH EPS 1/4 NPT
PRODUCT LABEL IDENTIFICATION
1/4 & 3/8
C ROSSC HECK ™ Safe Load Holding Valve
A
CC4M02NAEXSA CC4M0XXAEXSA
B
4
2
D
1
3
VALVE AND BASE:
VALVE LESS BASE: PRESSURE: 0 - 8 BAR 14 B 14 A
C
12 B 12 A
E
U.S. AND FOREIGN PATENTS PENDING
2
14B 14A
Simplified
12B 12A 1
12.37 (314.2) 5.72 (145.3) 4.10 (104.1) 4.60 (116.7) 5.11 (129.7)
13.01 (330.5) 6.84 (171.1) 5.20 (132.1) 5.80 (147.3) 4.87 (123.7)
3.41 (85.6)
3.55 (90.2)
F IN
SCHEMATICS 4
1/2 & 3/4 Dimension – Inches (mm)
EXH
Inlet Exhaust
EPS
External Pilot Supply
TPR
Trapped Pressure Release
3
Port Size
Flow Rates Pilot Valve 14 A
Pilot Valve 12 B
Ext Pi
CV
Basic
Inlet Outlet Exhaust Size
1-2 1-4 2-3 4-3
1/4
1/4
1/4
0
1
1
0.8 0.8
3/8
3/8
3/8
0
1
1
0.8 0.8
1/2
1/2
1/2
2
1.9
2
2
1.9
3/4
3/4
3/4
2
1.9
2
2
1.9
Trapped Pressure Release Valve
Valve Receptacle Pinout PORT 4 PORT 1
PORT 3
B
3 1
4
A
4 5
5
PORT 2 2
2
3
3
C
Valve Wiring Diagram
Pilot Valve 14 B
B
A
GRAY
4
5
2 WHITE
3
BLUE
BLUE
1 BROWN
2
5
4
3 BLUE
BLACK
4 BLACK
5 3
WHITE
14B 14A
Flow Control
2
WHITE
1
CC4 Series Cylinder Stop Load Holding Valve
C
1 GRAY
Application Example
Pressure Gauge
4
2 1
Pilot Valve 12 A
1 5
Trapped Pressure Release Valve
BLACK GRAY
4
1 3
2
Pressure Regulator Flow Control
BROWN BLUE
12B 12A
BROWN
BLUE BLUE
2
BROWN
+
SOL 12A
SOL 14A
+ -
+
SOL 14B
SOL 12B
+ -
BROWN
Filter
BLUE
L-O-X® Lockout Valve
POWER COMMON SENSOR A SENSOR B GROUND
BROWN BLUE WHITE BLACK GREEN
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Pneumatic Fluid Power - General Rules and Safety Requirements for Pneumatic Systems and their Components
- Safety related parts of a control system - Part 2 Safety of Machinery -Electrical equipment of machines - Part 1
Safety of Machinery - Safety related parts of a control system - Part 1 Safety of Machinery
Langen, July 28, 2017
Dietrich Warmbier Global Safety Product Manager
Signature
#ERTIÚCATION"ODYFOR4YPE4ESTING DGUV Test Prüf- und Zertifizierungsstelle Hebezeuge, Sicherheitskomponenten und Maschinen Fachbereich Holz und Metall Kreuzstraße 45 40210 Düsseldorf Tel.: 0211 8224-16910 Fax: 0211 8224 26910 [email protected] http://www.dguv.de/fb-holzundmetall/pruefstellen/hebezeuge Reference: HSM .OTIÚED"ODYWITHINTHE%UROPEAN5NION )$ .O #ERTIÚCATIONPENDING
Authorized person for the compilation of technical documentation: Klaus Goebel ROSS EUROPA GmbH Robert-Bosch-Strasse 2 63225 Langen / Germany
EN ISO 4414:2010-11:
EN60204-1:2006-06:
EN ISO 13849-2:2012:
EN ISO 13849-1:2015:
Applied harmonized standards:
are in full accordance with the following Directive: Machinery Directive 2006/42/EC
Herewith we declare that all ROSS® double valve CC4
(Translation from German-language Original)
Declaration of CE Conformity
Telefon: (06103) 7597- 0 • Fax: (06103) 74694 • e-mail: [email protected] • www.rosseuropa.com Sitz: Langen • AG: Langen, B412 • Geschäftsführer: Ralf W. Dinkel
ROSS EUROPA GmbH • Robert-Bosch-Strasse 2 • D-63225 Langen
Sicherheit von Maschinen -Elektrische Ausrüstung von Maschinen Teil 1 Fluidtechnik -Allgemeine Regeln und sicherheitstechnische Anforderungen an Pneumatikanlagen und deren Bauteile
EN60204-1:2006-06: EN ISO 4414:2010-11:
Langen, 28. Juli 2017
Dietrich Warmbier Global Safety Product Manager
Unterschrift
:ERTIÚZIERUNGSSTELLEDER"AUMUSTERPRÔFUNG DGUV Test Prüf- und Zertifizierungsstelle Hebezeuge, Sicherheitskomponenten und Maschinen Fachbereich Holz und Metall Kreuzstraße 45 40210 Düsseldorf Tel.: 0211 8224-16910 Fax: 0211 8224 26910 [email protected] http://www.dguv.de/fb-holzundmetall/pruefstellen/hebezeuge Kurzzeichen: HSM Benannte Stelle der EU, Kennnummer: 0393 :ERTIÚZIERUNGEINGELEITET
Bevollmächtigter für die Zusammenstellung der technischen Unterlagen: Klaus Goebel Fa. ROSS EUROPA Robert-Bosch-Straße 2 63225 Langen
EN ISO 13849-2:2012:
Sicherheit von Maschinen -Sicherheitsbezogene Teile von Steuerungen Teil 1 Sicherheit von Maschinen -Sicherheitsbezogene Teile von Steuerungen Teil 2
EN ISO 13849-1:2015:
Angewendete harmonisierte Normen:
den einschlägigen Bestimmungen folgender Richtlinien entsprechen: Maschinenrichtlinie 2006/42/EG
Hiermit erklären wir, dass alle ROSS®-Zwillingsventile der Baureihe CC4
(Originalfassung)
CE-Konformitätserklärung
Telefon: (06103) 7597- 0 • Fax: (06103) 74694 • e-mail: [email protected] • www.rosseuropa.com Sitz: Langen • AG: Langen, B412 • Geschäftsführer: Ralf W. Dinkel
ROSS EUROPA GmbH • Robert-Bosch-Strasse 2 • D-63225 Langen
CROSSCHECK CC4 SERIES Operating Instructions
3
CROSSCHECK CC4 SERIES Operating Instructions
1. About this Documentation
f 6. Notes on Safety
These instructions contain important information for the safe and appropriate assembly and commissioning of the product. f 5HDG WKHVH LQVWUXFWLRQV DOO WKH ZD\ WKURXJK SDUWLFXODUO\ VHFWLRQ} q6DIHW\ instructions,” before working with the product. Additional documentation: • 6,67(0$OLEUDULHV • '*89 IRUPHUO\%* FHUWLƂFDWH *HUPDQSURIHVVLRQDODVVRFLDWLRQ • Technical documents For more information see last page for contact information, or visit www.rosscontrols.com. f ,Q DGGLWLRQ REVHUYH DOO DSSOLFDEOH ORFDO DQG QDWLRQDO UHJXODWLRQV RQ DFFLGHQW prevention and on environmental protection.
The product has been manufactured according to the accepted rules of current technology. There is risk of injury or damage if the following safety instructions and warnings given in this instruction manual are not observed.
6.1. Intended Use
Product label identification & product key identification example, see page 2.
The CROSSCHECKTM && 6HULHV GRXEOH YDOYHV DUH VDIHW\ FRPSRQHQWV GHVLJQHG DQG PDQXIDFWXUHGLQDFFRUGDQFHZLWK0DFKLQHU\'LUHFWLYH(&DQGEHDUWKH&( mark. The CROSSCHECKTM OLQH RI GRXEOH YDOYHV DUH UHGXQGDQW SRUWHG SRVLWLRQ FORVHGFHQWHU SQHXPDWLF YDOYHV WKDW DUH GHVLJQHG WR PHHW WKH QHHGV DQG UHTXLUHPHQWV RI VDIH F\OLQGHU VWRS DQG ORDGKROGLQJ DSSOLFDWLRQV IRU PDFKLQHU\ ZLWK SQHXPDWLFFRQWUROV7\SLFDOO\WKHVHYDOYHVDUHLPSOHPHQWHGWRPHHWWKH&DWHJRU\ and/or Performance Level e requirements of a machine’s (or system’s) safety circuit DVGHWHUPLQHGE\DULVNDVVHVVPHQWRIWKHKD]DUGVDQGWDVNVUHTXLUHGRIHPSOR\HHV WKDWLQWHUDFWZLWKWKHPDFKLQH V\VWHP 7KHYDOYHLVFRQVWUXFWHGZLWKWLJKWVHDOLQJ GLUWWROHUDQWSRSSHWW\SHLQWHUQDOV7KHYDOYHDOVRKDVDQLQWHJUDWHGWUDSSHGSUHVVXUH release system. After stopping a cylinder and performing lockout/tagout, trapped SUHVVXUHFDQEHUHOHDVHGE\ZD\RIPDQXDOO\RSHUDWHGZD\YDOYHVORFDWHGDWHDFK HQGRIWKHYDOYHpVVXEEDVHtRQHHDFKSHUYDOYHRXWOHWSRUW f 6HHVHFWLRQq7HFKQLFDO'DWDrIRUWKHVWDQGDUGVDQGWHVWYDOXHVFRPSOLHGZLWK DQG DGKHUHG WR E\ WKH SURGXFW 6HH WKH GHFODUDWLRQ RI FRPIRUPLW\ IRU SURGXFW UHOHYDQW(&GLUHFWLYHV The CROSSCHECKTM &&6HULHVYDOYHLVGHVLJQHGWRFRQWUROWKHGLUHFWLRQRIDLUƃRZLQWR DQGRXWRIDGRXEOHDFWLQJF\OLQGHURURWKHUSQHXPDWLFDFWXDWRULQRUGHUWRGULYHWKH cylinder forward or backward to suit the requirements of the machine operation until signaled to shut off and trap pneumatic energy in the cylinder in order to stop cylinder PRWLRQ ORDG KROGLQJ 7KXV UHGXFLQJ WKH SRWHQWLDO KD]DUG RI XQH[SHFWHG F\OLQGHU PRWLRQGXULQJHPSOR\HHDFFHVVIRUSURGXFWLRQUHODWHGWDVNVDQGRUPLQRUVHUYLFLQJ 7XUQLQJRIIDOOVROHQRLGVRQWKHCROSSCHECKTM &&6HULHVYDOYHUHWXUQVWKHYDOYH WRWKHFHQWHUSRVLWLRQLQRUGHUWRVWRSWKHF\OLQGHUPRWLRQWKLVDOVRDOORZVMRJJLQJRI the cylinder. However, the CROSSCHECKTM&&6HULHVYDOYHRIIHUVWKLVIXQFWLRQZLWKWKH required level of control expected of the machine’s (system’s} safety control system XSWR&DWHJRU\3/H6XFKDFRQWUROV\VWHPPXVWEHFDSDEOHRILQKLELWLQJIXUWKHU operation of the valve in the event of a fault within the valve. The safety function of the CROSSCHECKTM &&6HULHVYDOYHLVWREORFNIXUWKHUVXSSO\RI pneumatic energy through the valve and also to block the exhaust of any pneumatic energy from the cylinder lines and cylinder downstream of the valve whenever the YDOYHLVVKXWRIIRUDIDXOWRFFXUVZLWKLQWKHYDOYH 6HHVHFWLRQ 127( 7KHCROSSCHECKTM&&6HULHVYDOYHFDQQRWSUHYHQWORVVRISQHXPDWLFHQHUJ\ (compressed air) from downstream of the valve that may occur through leaks in pipe RU WXEH ƂWWLQJV EURNHQ SLSLQJ RU WXELQJ F\OLQGHU URG VHDOV F\OLQGHU SLVWRQ VHDOV RU other control valves. The CROSSCHECKTM && 6HULHV YDOYHV DUH GHVLJQHG IRU H[WHUQDO PRQLWRULQJ IRU safe, redundant operation of the valves. The CROSSCHECKTM && 6HULHV YDOYHV DUH constructed of redundant, poppet type valves, and have an overall function of a double VROHQRLGSLORWRSHUDWHGVSULQJFHQWHUHGYDOYH(DFKVLQJOHYDOYHLQWKHCROSSCHECKTM CC4 SHULHV LV HTXLSSHG ZLWK D +DOOHIIHFW PLGSRVLWLRQ VHQVRU 0RQLWRULQJ ERWK RI WKHVHVHQVRUVRQHDFKDFWXDWLRQDQGGHDFWXDWLRQRIWKHCROSSCHECKTM&&6HULHV YDOYHSURYLGHVDGLDJQRVWLFFRYHUDJHXSWR 0RQLWRULQJRIWKHVHVHQVRUVPXVWEH SHUIRUPHGE\DQH[WHUQDOPRQLWRULQJV\VWHP6XFKDPRQLWRULQJV\VWHPLVEHFDSDEOH RI LQKLELWLQJ WKH RSHUDWLRQ RI WKH YDOYH7KH VDIHW\ FRQWURO V\VWHP PXVW GHHQHUJL]H the valve’s solenoids in the event of a fault within the valve and/or within the safety control system and check for achievement of the center position before allowing an DWWHPSWWRUHHQHUJL]HWKHYDOYH:KHQDIDXOWRFFXUVYDOYHUHVHWLVDFFRPSOLVKHGE\ GHHQHUJL]LQJDOORIWKHYDOYHpVVROHQRLGV
3. Prerequisites for Use of the Product
6.1.1. Safety Function According to ISO 13849 and EN 692
f 0DNH WKHVH RSHUDWLQJ LQVWUXFWLRQV DYDLODEOH WR WKH HQJLQHHU DQG DVVHPEO\ technician of the machine/system in which the product will be used. f Keep these operating instructions for the entire product life cycle.
CROSSCHECKTM&&6HULHVYDOYHVDUHGHVLJQHGLQDFFRUGDQFHZLWKWKHUHTXLUHPHQWV OLVWHG LQ ,62 DQG 7KHLUqIDLOWRVDIHr VDIHW\ IXQFWLRQ LV HQVXUHG HYHQ LQ case of a single fault within the valve (e.g., caused by wear, contamination, or similar situations). The safety function of the CROSSCHECKTM&&6HULHVYDOYHLVWREORFNDOOWKHYDOYHpV ports in order to stop motion of the cylinder it is controlling (load holding). The valve can only drive the cylinder it is controlling forward or backward when the two internal YDOYHHOHPHQWVDUHVXFFHVVIXOO\DFWXDWHGVLPXOWDQHRXVO\ HLWKHUVROHQRLGV$ % RU$ % 2WKHUZLVHWKHCROSSCHECKTM&&6HULHVYDOYHZLOOVKXWRIIDOOSRUWV when the valve is shut off or if only one of the two internal valve elements is actuated. A fault in the system where only one valve actuates when switching on or only one GHDFWXDWHV ZKHQ VZLWFKLQJ RII SUHYHQWV DLU IURP EHLQJ VXSSOLHG GRZQVWUHDP DQG simultaneously blocks the exhaust of any air that is already downstream in the cylinder OLQHVDQGF\OLQGHU0RQLWRULQJRIWKHWZR+DOOHIIHFWPLGSRVLWLRQVHQVRUVE\WKHXVHUpV external safety monitoring system makes it possible to detect these fault situations and WRVKXWRIIDQGSUHYHQWIXUWKHUHOHFWULFDOHQHUJL]DWLRQRIWKHVROHQRLGV The control outputs of the safety system must be designed and constructed to meet the Category and/or Performance Level requirements of the safety system, as determined E\WKHULVNDVVHVVPHQWRIWKHPDFKLQH1RUPDOO\WKHRXWSXWWRWKHVROHQRLGVLVDGXDO channel output from a safety relay or safety PLC.
1.1. Warning Notices in these Operating Instructions ,Q WKHVH RSHUDWLQJ LQVWUXFWLRQV ZDUQLQJ QRWLFHV SUHFHGH VHFWLRQV ZLWK KDQGOLQJ requirements which incur risks of personal injury or material damage. Warnings are structured as follows:
SIGNAL WORD Type or source of hazard! Consequences f Measures to avert danger • • • • •
Warning triangle:,QGLFDWHVDULVNRIIDWDORUVHYHUHLQMXULHV Signal word: ,QGLFDWHVWKHVHYHULW\RIWKHGDQJHU Type or source of hazard:6WDWHVWKHW\SHRIGDQJHURUWKHVRXUFHRIWKHKD]DUG Consequences: Describes possible consequences of ignoring the warning. Measures to avert danger:},QGLFDWHVKRZWRDYRLGWKHGDQJHU,WLVHVVHQWLDOWKDW the measures to avert danger are complied with.
DANGER
Indicates an imminent and serious danger that will result in severe or even fatal injury if you fail to avoid it.
WARNING
Indicates a possible danger that could result in severe or even fatal injury if you fail to avoid it.
CAUTION
ATTENTION
Indicates a danger that may result in minor to moderate injuries if you fail to avoid it. Indicates potential property damage that may be incurred by the product or its surroundings if you fail to avoid it.
2. Product Identification Date of manufacture and site of manufacture are permanently stamped:
Manufacturing site
Site abbreviation
(L) ROSS CONTROLS USA (G) ROSS EUROPA (RB) ROSS UK (J) ROSS ASIA (B) ROSS SOUTH AMERICA (C) ROSS CONTROLS CHINA (RCI) ROSS CONTROLS INDIA See back page for ROSS addresses.
Valve printing (example May 2016) (5 16 L) (5 16 G) (5 16 RB) (5 16 J) (5 16 B) (5 16 C) (5 16 RCI)
3.1. Qualified Personnel Assembly, installation, commissioning, maintenance, and decommissioning should RQO\ EH FDUULHG RXW E\ TXDOLƂHG SHUVRQQHO WKDW KDYH WKH UHTXLUHG NQRZOHGJH RI DQG experience in dealing with electrical and pneumatic control technology.
4. Package Contents ,WHPVLQFOXGHG • CROSSCHECKTM&&6HULHVYDOYH • Operating instructions
5. Service, Repair, and Maintenance f ,QFDVHRIWHFKQLFDOSUREOHPVRUDUHTXLUHGUHSDLUSOHDVHFRQWDFW\RXUORFDO5266 UHSUHVHQWDWLYH ,I XVHG SURSHUO\ WKH CROSSCHECKTM CC4 6HULHV YDOYHV ZLOO QRW UHTXLUHPDLQWHQDQFH8QOHVVRWKHUZLVHUHTXLUHG5266® recommends performing a functional test at least annually (see 8.1 Test Procedure).
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CROSSCHECK CC4 SERIES Operating Instructions 6.1.2. Common Cause Failure – CCF The product has been engineered and manufactured according to the fundamental and SURYHQVDIHW\SULQFLSOHVRI,62 DQG Common Cause Failures (CCF) are failures of different components, resulting from a single event. CCF are not to be confused with cascading faults or common mode faults. Common cause failures can cause loss of the safety function, especially in dual channel circuits where both channels could fail simultaneously due to a single event. s 0DLQWDLQFRPSUHVVHGDLUTXDOLW\LHƂOWUDWLRQSUHVVXUHUHJXODWLRQOXEULFDWLRQ • Avoid compressor oils that can cause valve seals to swell, soften, or otherwise deteriorate. • Operate within prescribed temperature limits. s ,QVWDOO WKH YDOYH VXFK WKDW WKH QRUPDO VWURNH WUDYHO RI WKH YDOYH HOHPHQWV DUH perpendicular to the main direction of machine vibration and/or mechanical shock. s 'RQRWXVHDWHVWSXOVHORQJHUWKDQDOORZHGE\WKH7HFKQLFDO6SHFLƂFDWLRQV s $YRLGH[WHUQDOPDJQHWLFƂHOGV • Do not plug the valve exhaust port. • 8VHRQO\KLJKƃRZQRQFORJJLQJVLOHQFHUVZLWKVLPLODURUKLJKHUVSHFLƂFDWLRQVDV 5266® silencers.
6.1.3. Diagnostic Coverage $ GLDJQRVWLF FRYHUDJH RI LV DFKLHYDEOH WKURXJK DSSURSULDWH LQWHJUDWLRQ RI WKH CROSSCHECKTM&&6HULHVYDOYHLQWRWKHVDIHW\FRQWUROV\VWHP7KHPRQLWRULQJV\VWHP PXVWFKHFNIRUWKHSURSHUFKDQJHRIVWDWHRIHDFKYDOYHVHQVRU 6HQVRU$ 6HQVRU% with each change of state of the safety control system outputs to the valve solenoids 6ROHQRLGV $ % RU 6ROHQRLGV $ % 'HWHFWLRQ RI D IDXOW E\ WKH VDIHW\ FRQWURO V\VWHP PXVW WULJJHU D VKXWRII RI WKH VDIHW\ FRQWUROOHUpV RXWSXWV WR DOO RI WKH YDOYHpVVROHQRLGV $%$ % VHHVHFWLRQ
6.1.4. Fault Modes 1RWH WKDW QRUPDO RSHUDWLRQ UHTXLUHV WKDW VROHQRLGV $ % EH HQHUJL]HG simultaneously for switching the CROSSCHECKTM&&6HULHVYDOYHRQLQRUGHUWRGULYHWKH F\OLQGHUIRUZDUG SRUWSUHVVXUL]HGDQGSRUWH[KDXVWHG RUWKDWVROHQRLGV$ % EHHQHUJL]HGVLPXOWDQHRXVO\LQRUGHUWRGULYHWKHF\OLQGHUEDFNZDUG SRUWSUHVVXUL]HG DQG SRUW H[KDXVWHG 'HHQHUJL]LQJ DOO RI WKH YDOYHpV VROHQRLGV VLPXOWDQHRXVO\ switches the CROSSCHECKTM&&6HULHVYDOYHRIIDQGWUDSVSUHVVXUHRQSRUWV LQ RUGHUWRVWRSWKHF\OLQGHU ORDGKROGLQJ Faults that could occur during normal operation: 6ROHQRLGV$ %HQHUJL]HGVLPXOWDQHRXVO\ 62162)) 62))621 621621 6ROHQRLGV$ %HQHUJL]HGVLPXOWDQHRXVO\ 62162)) 62))621 621621 $OOVROHQRLGVGHHQHUJL]HGVLPXOWDQHRXVO\ 62162II 62))621 62))62))
WARNING Risk of Injury! Misuse may result in injury or damage. f The product must be used exclusively as intended. Foreseeable misuse includes: • Use outdoors • Bypassing the safety function or diagnostics s )DLOLQJ WR XWLOL]H WKH RQERDUG PLGSRVLWLRQ VHQVRUV WR YHULI\ YDOYH RSHUDWLRQ RQ HYHU\F\FOHtHQHUJL]LQJDQGGHHQHUJL]LQJ • Allowing continued operation of the valve when one or both valve shifted signals IURPWKHRQERDUGPLGSRVLWLRQVHQVRUV DUHQRWFRQƂUPHG • Use in reverse operation (reversal of supply and exhaust air) s 2SHUDWLRQLQORZGHPDQGPRGHSHU,(& • Operating at pressures below minimum operating pressure or above maximum operating pressure.
6.2. Responsibilities of the System Owner
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Observe the information on assembly and operating conditions listed in the operating instructions or the data sheet. &RPSO\ZLWKWKHIXUWKHUUHTXLUHPHQWVRI,62 HJ&&)'&3/UVRIWZDUH LI\RXLQWHQGWRXVHWKHSURGXFWLQKLJKHUFDWHJRULHV RU 0DNHVXUHWKDWWKHPD[LPXPQXPEHURIVZLWFKLQJF\FOHV %') within the service life TmLVQRWH[FHHGHG,IWKHH[SHFWHGQXPEHURIVZLWFKLQJF\FOHVIRUDFRPSRQHQW exceeds the B' value during its period of use, suitable replacement intervals have WREHVSHFLƂHG
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6ZLWFKWKHYDOYHDWOHDVWRQFHDPRQWK to ensure its proper operation. 0DNHVXUHWKDWWKHIXQGDPHQWDODQGSURYHQVDIHW\SULQFLSOHVLQDFFRUGDQFHZLWK ,62 IRULPSOHPHQWDWLRQDQGRSHUDWLRQRIWKHFRPSRQHQWDUHFRPSOLHGZLWK 0DNHVXUHWKDWWKHSHUPLVVLEOHVZLWFKRQDQGVZLWFKRIISXOVHVIRUIHHGEDFNIUHH operation of the pneumatic devices are observed. ,I\RXRSHUDWHWKHCROSSCHECKTM&&6HULHVYDOYHWRJHWKHUZLWKDQHOHFWULFWZR KDQGFRQWUROLWPXVWFRPSO\ZLWKWKH(1VWDQGDUG6HOHFWLRQDQGLQVWDOODWLRQ RI WKLV WZRKDQG FRQWURO PXVW WDNH SODFH LQ DFFRUGDQFH ZLWK WKH PDQXIDFWXUHUpV VSHFLƂFDWLRQV
6.3. Safety Instructions •
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When implementing surge suppression measures, be sure to check whether or not this extends the valve shut off response time which could extend the machine stopping time. ,Q FDVH RI KLJK OHYHOV RI PDFKLQH YLEUDWLRQ XVH DSSURSULDWH YLEUDWLRQUHGXFLQJ elements when installing the valve. 6XSSO\WKHSURSHUYROWDJHDVRYHUYROWDJHVLWXDWLRQVFDQUHVXOWLQVROHQRLGEXUQRXW 0DNH VXUH WKDW WKH VLOHQFHUpV ƃRZ FDSDFLW\ LV QRW UHVWULFWHG DV WKLV FRXOG DIIHFW system performance. ,IUHTXLUHGUHSODFHWKHVLOHQFHUH[FOXVLYHO\ZLWKDFRUUHVSRQGLQJ5266PRGHO
7. Assembly and Installation CAUTIONS Risk of injury due to installation while pressurized or with live parts! ,QVWDOODWLRQ ZKLOH SUHVVXUL]HG RU ZLWK HOHFWULFDO SRZHU VZLWFKHG RQ FDQ UHVXOW LQ LQMXULHVGXHWRVXGGHQSUHVVXUHEXLOGXSRUHOHFWULFVKRFN f 'HHQHUJL]HDQGGHSUHVVXUL]HWKHUHOHYDQWV\VWHPSDUWVEHIRUHLQVWDOOLQJWKH valves. f 6HFXUHWKHV\VWHPWRSUHYHQWLWEHLQJVZLWFKHGEDFNRQDJDLQ
ATTENTION Destruction of components! Chemical substances can damage the surface, the markings and the seals of the device. f ,QVWDOOWKHYDOYHVXFKWKDWLWLVSURWHFWHGDJDLQVWWKHHIIHFWVRIFKHPLFDOV Damage to the device through storage at incorrect temperatures! The storage temperature represents the permissible ambient temperature and depends on the type of valve in question. f 2EVHUYHWKHWHPSHUDWXUHLQIRUPDWLRQLQFKDSWHUq7HFKQLFDO'DWDr
7.1. Mechanical Installation 6HFXUHWKHYDOYHXVLQJWKHWKURXJKKROHVLQWKHYDOYHEDVH5HIHUWRSDWWHUQIRUWKH UHTXLUHGGLPHQVLRQVVHHGLPHQVLRQDOGUDZLQJVRQSDJH
7.2. Pneumatic Installation &RQQHFWWKHFRPSUHVVHGDLUVXSSO\WRSRUW&RQQHFWSRUWDQGSRUWWRWKH downstream portion of the circuit.
6.1.5. Foreseeable Misuse
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7.3. Pneumatic and Electrical Connections (OHFWULFDO FRQQHFWLRQV WR WKH VROHQRLGV DQG VHQVRUV DUH PDGH ZLWK PDOH SLQ 0 UHFHSWDFOHV RQ WKH YDOYH 6HH 3LQRXWV RQ SDJH )HPDOH FRQQHFWRUV DQG FDEOHV aresold separately. The cables and cable connections as well as the electrical control for the double valves must comply with the applicable safety regulations.
8. Commissioning and Operation CAUTIONS Damage to health due to loud noise! Levels above 70 dB(A) may lead to damage to health! f Always wear ear protectors when working on the product. %HIRUH FRPPLVVLRQLQJ WKH LQVWDOODWLRQ KDV WR EH FDUHIXOO\ LQVSHFWHG E\ D TXDOLƂHG trained professional. 0DNH VXUH WKDW WKH WHFKQLFDO VSHFLƂFDWLRQV PDWFKHV WKH RSHUDWLQJ FULWHULD RI WKH machine and/or the pneumatic system. Always set the compressed air supply to a level that ensures that the minimum RSHUDWLQJSUHVVXUHLVDGKHUHGWR VHHVHFWLRQ7HFKQLFDO6SHFLƂFDWLRQV
8.1. Test Procedure 8VH WKLV WHVW SURFHGXUH WR FRQƂUP YDOYH DQG VHQVRU IXQFWLRQ 7KH WHVW SURFHGXUH EHORZ DVVXPHV DOO SUHVVXUH LV UHPRYHG IURP WKH V\VWHP DQG DOO VROHQRLGV DUH GH HQHUJL]HGSULRUWREHJLQQLQJWKHSURFHGXUH
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CROSSCHECK CC4 SERIES Operating Instructions
Design:5HGXQGDQW&ORVHG&HQWHUVSULQJFHQWHUHGGLUHFWLRQDOYDOYHHOHPHQWVRI poppet construction. Mounting Type: 6XEEDVHPRXQWHG Actuation: 6ROHQRLGSLORWRSHUDWHGZLWKVSULQJUHWXUQWRFHQWHU7ZRVROHQRLGVSHUYDOYH HOHPHQWtIRXUWRWDO(QHUJL]HVROHQRLGV$DQG%WRSUHVVXUL]HSRUWDQGH[KDXVW SRUW(QHUJL]HVROHQRLGV$DQG%WRSUHVVXUL]HSRUWDQGH[KDXVWSRUW Mounting Type: 6XEEDVHPRXQWHG Pilot Solenoid:9HUVLRQDVSHU9'(5DWHGIRUFRQWLQXRXVGXW\ (OHFWULFDOFRQQHFWLRQDFFRUGLQJWR(1)RUP&(QFORVXUHUDWLQJDFFRUG LQJWR',1,3 Standard Voltages: YROWV'& Pilot Solenoids Power Consumption:ZDWWVSHUVROHQRLG tRQO\RIZKLFK VKRXOGEHHQHUJL]HGDWRQHWLPH Electrical Connections: Three SLQ0FRQQHFWRUV Mid-Position Sensors:SHUYDOYH+DOOHIIHFWGLVFUHHW P$ Ambient Temperature: WR) &WR& Medium Temperature:WR) &WR& )RUWHPSHUDWXUHVEHORZ& ) WKHFRPSUHVVHGDLUPXVWEHGULHGDFFRUGLQJWR ,62FODVV Flow Media: &RPSUHVVHGDLU LQHUWJDVHV ƂOWHUHGLQDFFZLWK,62 FODVV P ZLWKRUZLWKRXWLQOLQHOXEULFDWLRQ PLQHUDORLOVDFFRUGLQJWR,62 ,629*YLVFRVLW\FODVV Inlet Pressure: With Internal Pilot Supply:WRSVLJ WREDU With External Pilot Supply:WRSVLJ WREDU Pilot Supply Pressure: WRSVLJ WREDU 0XVWEHHTXDOWRRUJUHDWHUWKDQ inlet pressure. Static Pressure: WRSVLJ WREDU Mounting Orientation:$Q\EXWKRUL]RQWDOO\ZLWKVROHQRLGVRQWRSLVSUHIHUUHG Monitoring: Dynamic, cyclical, external with customer supplied equipment. 0RQLWRULQJVKRXOGFKHFNVWDWHRIERWKYDOYHPLGSRVLWLRQVHQVRUVZLWKDQ\DQGDOO changes in state of valve control signals. Shock Test (based on DIN EN 60068-2-27): s $FFHOHUDWLRQ &RQVXOW5266 s 6KRFNGXUDWLRQ &RQVXOW5266 s 6KRFNZDYHIRUP &RQVXOW5266 s 9LEUDWLRQWHVW EDVHGRQ',1(1 s )UHTXHQF\ &RQVXOW5266 s $PSOLWXGH &RQVXOW5266 B10D Value according to ISO 13849-1 and -2:6HUYLFHOLIHSDUDPHWHUPHDVXUHG DFFRUGLQJWR5266(QJLQHHULQJ6WDQGDUG/DERUDWRU\7HVW3URFHGXUHV6HFWLRQ 6L]H %' PLOOLRQF\FOHV 6L]H %' &RQVXOW5266 Mid-position Sensors: T' &RQVXOW5266 Maximum Cycle Rate: &RQVXOW5266+]PHDVXUHGZLWKRXWYROXPH7KHVZLWFKLQJ frequency decreases depending on the volume to be controlled. Sound Pressure Level [dB(A)]:&RQVXOW52667KHVRXQGSUHVVXUHOHYHOis LQƃXHQFHGE\WKHLQGLYLGXDOV\VWHPVXVHGIRUUHGXFWLRQRIQRLVHHPLVVLRQV8VH RQO\VLOHQFHUVZLWKH[KDXVWƃRZFDSDELOLW\JUHDWHUWKDQWKHH[KDXVWFDSDELOLW\RIWKH valve, do not restrict the valve exhaust. Use of the product without the silencer is not recommended. Minimum Operation Frequency: Once a month, to ensure proper function operation.
Momentarily energize solenoids 12A & 12B
Energize solenoid 12A De-energize solenoid 12A Energize solenoid 12B De-energize solenoid 12B Energize solenoid 14A De-energize solenoid 14A Energize solenoid 14B De-energize solenoid 14B 13 14 15 16 17 18 19 20
9
10 11
8
12
Line Line
Line Line
0 0 On Off
On On
On Off Off Off
Off Off
Off Off
0 Line Off Off On On
Line Line Off Off On On 7
Step Fault Conditions Precedures Acctions #
If not already retracted.
None None Retract Stays put Extend Stays put Partial retract Retract Partial extend Extend None Off On Off On Off On Off then On Off Off then On Off On Off On Off On Off On Off then On Off Off then On Off On 0 0 0 0 Line Line 0 0 Line Line 0 0 Off Off Off Off On Off Off Off Off Off On Off Off Off On Off Off Off Off Off On Off Off Off
Supply pressure to port 1 Apply power to the valve position sensors Energize solenoids 12A & 12B De-energize solenoids 12A & 12B Energize solenoids 14A & 14B De-energize solenoids 14A & 14B Momentarily energize solenoids 12A & 12B Energize solenoids 12A & 12B Momentarily energize solenoids 14A & 14B Energize solenoids 14A & 14B De-energize solenoids 14A & 14B 1 2 3 4 5 6
Step #
Normal Valve & Sensor Function Precedures Acctions
Sol 12A
Sol 12B
Sol 14A
Sol 14B
Outlet pressure Port 2 Port 4
Cylinder Sensor condition Notes Sensor A Sensor B Action
.
Sol Sol Sol Sol Outlet pressure Sensor condition Cylinder Notes 12A 12B 14A 14B Port 2 Port 4 Sensor A Sensor B Action On On Off then Off then Partial Energize only long enough Line Line then then Off Off On On retract for a partial stroke. off off On Off Off Off Line Line Off On None Fault Off Off Off Off Line Line On On None No fault Off On Off Off Line Line On Off None Fault Off Off Off Off Line Line On On None No fault Off Off On Off Line Line Off On None Fault Off Off Off Off Line Line On On None No fault Off Off Off On Line Line On Off None Fault Off Off Off Off Line Line On On None No fault
10. Technical Specifications
6WHSVtDUHWRFRQƂUPYDOYHDQGVHQVRUIXQFWLRQGXULQJIDXOWFRQGLWLRQV Energize only long enough for a partial stroke. Finish the stroke Energize only long enough for a partial stroke. Finish the stroke.
6WHSVtDUHWRFRQƂUPQRUPDOYDOYHDQGVHQVRUIXQFWLRQ
Results from the test procedure other than those listed above could indicated a valve PDOIXQFWLRQ6HHVHFWLRQ6HUYLFH5HSDLUDQG0DLQWHQDQFH Failure of the internal valve elements to shift synchronously leads to a fault in the CROSSCHECKTM&&6HULHVYDOYH7KLVFRXOGKDSSHQIRUDYDULHW\RIUHDVRQVVXFKDV • Defective piston seals, s 0DLQYDOYHHOHPHQWVH[SHULHQFLQJDVZLWFKLQJGHOD\GXHWRGLUWRUUHVLQRXVRLO s ,QVXIƂFLHQWHOHFWULFDOVLJQDOVWRYDOYHVROHQRLGV VXLWDEOHYROWDJHQRWDYDLODEOH • Receipt of signals at solenoids not synchronous, • Pilot valves experiencing a switching delay due to damaged components, dirt, or resinous oil, s ([FHVVLYHZDWHUEXLOGXSLQWKHYDOYH
11. Disposal Dispose of the valve in accordance with the applicable statutory regulations in your country.
9. Disconnecting and Removal CAUTIONS Risk of injury due to disconnecting pressurized or live parts. f 'LVFRQQHFWLQJDSQHXPDWLFFRPSRQHQWZKLOHWKHV\VWHPLVSUHVVXUL]HG or while electrical power is supplied can result in injury or death due to sudden pressure release, unexpected movement, or electric shock. f ,VRODWHDQGORFNRXWWKHHOHFWULFDODQGSQHXPDWLFV\VWHPVEHIRUH disconnecting the valves.
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CROSSCHECK CC4 SERIES Operating Instructions
CAUTIONS And WARNINGS PRE-INSTALLATION or SERVICE 1. Before servicing a valve or other pneumatic component, be sure that all sources of energy are turned off, the entire pneumatic system is shut off and exhausted, and all power sources are locked out (ref: OSHA 1910.147, EN 1037). 2. All ROSS products, including service kits and parts, should be installed and/or serviced only by persons having training and experience with pneumatic equipment. Because any installation can be tampered with or need servicing after installation, persons responsible for the safety of others or the care of equipment must check every installation on a regular basis and perform all necessary maintenance. 3. All applicable instructions should be read and complied with before using any fluid power system in order to prevent harm to persons or equipment. In addition, overhauled or serviced valves must be functionally tested prior to installation and use. If you have any questions, call your nearest ROSS location listed on the cover of this document. 4. Each ROSS product should be used within its specification limits. In addition, use only ROSS parts to repair ROSS products. WARNING: Failure to follow these directions can adversely affect the performance of the product or result in the potential for human injury or damage to property. FILTRATION and LUBRICATION 5. Dirt, scale, moisture, etc. are present in virtually every air system. Although some valves are more tolerant of these contaminants than others, best performance will be realized if a filter is installed to clean the air supply, thus preventing contaminants from interfering with the proper performance of the equipment. ROSS recommends a filter with a 5-micron rating for normal applications. 6. All standard ROSS filters and lubricators with polycarbonate plastic bowls are designed for compressed air applications only. Do not fail to use the metal bowl guard, where provided, to minimize danger from high pressure fragmentation in the event of bowl failure. Do not expose these products to certain fluids, such as alcohol or liquefied petroleum gas, as they can cause bowls to rupture, creating a combustible condition, hazardous leakage, and the potential for human injury or damage to property. Immediately replace a crazed, cracked, or deteriorated bowl. When bowl gets dirty, replace it or wipe it with a clean dry cloth. 7. Only use lubricants which are compatible with materials used in the valves and other components in the system. Normally, compatible lubricants are petroleum based oils with oxidation inhibitors, an aniline point between 180°F (82°C) and 220°F (104°C), and an ISO 32, or lighter, viscosity. Avoid oils with phosphate type additives which can harm polyurethane components, potentially leading to valve failure which risks human injury, and/or damage to property. AVOID INTAKE/EXHAUST RESTRICTION 8. Do not restrict the air flow in the supply line. To do so could reduce the pressure of the supply air below the minimum requirements for the valve and thereby cause erratic action. 9. Do not restrict a valve’s exhaust port as this can adversely affect its operation. Exhaust silencers must be resistant to clogging and must have flow capacities at least as great as the exhaust capacities of the valves. Contamination of the silencer can result in reduced flow and increased back pressure. WARNING: ROSS expressly disclaims all warranties and responsibility for any unsatisfactory performance or injuries caused by the use of the wrong type, wrong size, or an inadequately maintained silencer installed with a ROSS product. POWER PRESSES 10. Mechanical power presses and other potentially hazardous machinery using a pneumatically controlled clutch and brake mechanism must use a press control double valve with a monitoring device. A double valve without a self-contained monitoring device should be used only in conjunction with a control system which assures monitoring of the valve. All double valve installations involving hazardous applications should incorporate a monitoring system which inhibits further operation of the valve and machine in the event of a failure within the valve mechanism. ENERGY ISOLATION/EMERGENCY STOP 11. Per specifications and regulations, ROSS L-O-X® and L-O-X® with EEZ-ON® operation products are defined as energy isolation devices, NOT AS EMERGENCY STOP DEVICES.
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ROSS CONTROLS
U.S.A. Tel: +1-248-764-1800 Customer Svs. 1-800-GET-ROSS (438-7677) Technical Svs. 1-888-TEK-ROSS (835-7677) [email protected] www.rosscontrols.com
ROSS EUROPA GmbH Germany Tel: +49-6103-7597-0 [email protected] www.rosseuropa.com
ROSS ASIA K.K.
Japan Tel: +81-42-778-7251 www.rossasia.co.jp
ROSS UK Ltd.
United Kingdom Tel: +44-1543-671495 [email protected] www.rossuk.co.uk
ROSS CONTROLS INDIA Pvt. Ltd. India Tel: +91-44-2624-9040 [email protected]
ROSS SOUTH AMERICA Ltda. Brazil Tel: +55-11-4335-2200 [email protected] www.rosscontrols.com.br
ROSS FRANCE SAS
France Tel: +33-1-49-45-65-65 www.rossfrance.com
ROSS CONTROLS (CHINA) Ltd. China Tel: +86-21-6915-7961 [email protected] www.rosscontrolschina.com
ROSS CANADA
Canada Tel: +1-416-251-7677 [email protected] www.rosscanada.com 6077170 CANADA INC. AN INDEPENDENT REPRESENTATIVE
Printed in the U.S.A. – Rev. 01/11/18 © 2018 ROSS CONTROLS®. All Rights Reserved. Content subject to change. Form RC-CC4-OI
STANDARD WARRANTY All products sold by ROSS CONTROLS are warranted for a one-year period [with the exception of all Filters, Regulators and Lubricators (“FRLs”) which are warranted for a period of seven years] from the date of purchase to be free of defects in material and workmanship. ROSS’ obligation under this warranty is limited to repair or replacement of the product or refund of the purchase price paid solely at the discretion of ROSS and provided such product is returned to ROSS freight prepaid and upon examination by ROSS is found to be defective. This warranty becomes void in the event that product has been subject to misuse, misapplication, improper maintenance, modification or tampering. THE WARRANTY EXPRESSED ABOVE IS IN LIEU OF AND EXCLUSIVE OF ALL OTHER WARRANTIES AND ROSS EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES EITHER EXPRESSED OR IMPLIED WITH RESPECT TO MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. ROSS MAKES NO WARRANTY WITH RESPECT TO ITS PRODUCTS MEETING THE PROVISIONS OF ANY GOVERNMENTAL OCCUPATIONAL SAFETY AND/OR HEALTH LAWS OR REGULATIONS. IN NO EVENT IS ROSS LIABLE TO PURCHASER, USER, THEIR EMPLOYEES OR OTHERS FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES WHICH MAY RESULT FROM A BREACH OF THE WARRANTY DESCRIBED ABOVE OR THE USE OR MISUSE OF THE PRODUCTS. NO STATEMENT OF ANY REPRESENTATIVE OR EMPLOYEE OF ROSS MAY EXTEND THE LIABILITY OF ROSS AS SET FORTH HEREIN.
