CC4 Series Control Reliable Double Valves
EW N
352'8&7'$7$6+((7,1)250$7,21
CROSSCHECKTM CC4 Series Control Reliable Double Valves Safe Cylinder Stop and Load Holding Valve Designed for External Monitoring
up to CAT 4, PL e (certification pending)
Port Size 1/4 thru 3/4 ROSS’ new CROSSCHECKTM CC4 Series Safety directional valve is a redundant, externally monitored 4-ported, 3-position (closed center) pneumatic valve for Category 4, PL e applications, where stopping and holding a cylinder is necessary for safe operator access during production-related tasks. The valve is constructed with tight-sealing, dirt-tolerant poppet-type valve internals. Features & Benefits: • Closed Center Valve Function - allows full control of double-acting cylinders, including jog and load-holding functions • Redundant control with position feedback - can achieve Category 4, PL e, when used with proper safety controls • Designed for external monitoring - allows full safety control and feedback monitoring of cylinder control circuit • Mid-position sensing - for detection of safe, closed center position • ROSS poppet technology - fast, reliable, dirt-tolerant, face-sealing, low friction • LED indicators on solenoids - aids troubleshooting
HOW TO ORDER (Choose your options (in red) to configure your valve model number.)
CC4 Series Pressure Release Manual M Valve Only X
M
2
2
Basic Size 0 2 2 4 Basic Base Port Size Size Inlet Outlet 1/4 1/4 2 0 3/8 3/8 3 4 1/2 1/2 2 3/4 3/4 5 Valve Only (No Base) X
G
A Voltage 24 volts DC A Thread BSPP G NPT N Valve Only X
E
X
S
Communication None X Monitoring External E
4
A
2
Simplified 14B Schematic 14A
12B 12A 1
Revision Level
3
Pin Configuration Standard
S
Port Size
CV
Basic
Inlet Outlet Exhaust Size
1-2 1-4 2-3 4-3
Weight lb (Kg)
1/4
1/4
1/4
0
1
1
0.8 0.8 11.2 (5.1)
3/8
3/8
3/8
0
1
1
0.8 0.8 11.2 (5.1)
1/2
1/2
1/2
2
1.9
2
2
1.9 18.3 (8.3)
3/4
3/4
3/4
2
1.9
2
2
1.9 18.3 (8.3)
APPLICATIONS: Category 4 applications - e.g., cylinder stop & load holding applications. The CROSSCHECKTM CC4 Series valve is designed to be controlled by a safety controller or safety relay with dual channel outputs and the capability of monitoring the mid-position feedback sensors. The valve is a redundant valve and is driven by 4 solenoid pilot valves - two for extending and two for retracting.
Standard Specifications Construction: Redundant dual 4/3 closed center, poppets. Mounting Type: Sub-base mounted. Pilot Solenoid: Version as per VDE 0580. Rated for continuous duty. Enclosure rating according to DIN 400 50 IP 65. Standard Voltages: 24 volts DC. Pilot Solenoids Power Consumption (each solenoid): 3.5 watts. Electrical Connections: Three 5-pin, M12 connectors. Ambient Temperature: 40° to 140°F (+4°C to 60°C). Medium Temperature: 40° to 176°F (+4°C to 80°C). Flow Media: Compressed, filtered air according to ISO 8573-1:2010 [7:4:4].
Inlet Pressure: With Internal Pilot Supply: 60 to 120 psig (4 to 8 bar). With External Pilot Supply: 0 to 120 psig (0 to 8 bar). Pilot Supply Pressure: 60 to 120 psig (4 to 8 bar). Must be equal to or greater than inlet pressure. Static Pressure: 0 to 150 psig (0 to 10 bar). Mounting Orientation: Any, but horizontally with solenoids on top is preferred. Monitoring: Dynamic, cyclical, external with customer supplied equipment. Monitoring should check state of both valve mid-position sensors with any and all changes in state of valve control signals. Functional Safety Data: Pending.
This valve is not designed for controlling clutch/brake mechanisms on mechanical power presses, see DM2® Series D valves for mechanical power press applications.
5266 CONTROLS®
www.rosscontrols.com
CROSSCHECKTM CC4 Series Control Reliable Double Valves VALVE OPERATION
Abnormal Operation: When energizing, if both sets of valve internals do not shift synchronously (either on or off), the CROSSCHECKTM valve will block all ports. While in this fault condition, the valve cannot further pressurize or exhaust the cylinder lines. Also, as long as the fault condition exists, there will be a voltage output from the valve internals that did not shift from center, but there will not be an output from the other valve internals that did shift off center. This provides a detectable fault condition as both sensors need to agree in order to not indicate a fault.
14
4
1 3
Conditions at Start: Pressure applied to port 1, but all solenoids off. All ports (1, 2, 3, & 4) are blocked.
2
Sensing Midpoint
12
Port 2
14 B
12 B
Power + 24 VDC
EXHAUST
INLET
Operation Overview
14 A
Sensing Midpoint
1
12 A
Sensor A + 24 VDC 2
Port 2
Sensor B 4 + 24 VDC
5
Port 4
14 B
12 B
3
INLET
Sensing Midpoint
1 EXHAUST
INLET
Sensor A + 24 VDC 2
Sensor B 4 + 24 VDC
5 3
14 A
12 A
Ground
Common - 0 VDC
Port 4
Valve Faulted Side A, Left
14 B
12 B
14
EXHAUST
2
1 3
INLET
12 A
4
14 A
1 3
2
14 A
14 B
12 B
12
EXHAUST
INLET
Power + 24 VDC
Port 2
Port 2
14 B
12 B
2 12
Valve Faulted Side A, RIght
Sensing Midpoint
4
Port 2
1 3
Port 4
14
Sensing Midpoint
12 A
4
14 A
Normal Operation: Energizing both solenoids 14A & 14B causes the valve to shift and supply pressure to port 4 while exhausting pressure from port 2, thus, extending the cylinder. Conversely, energizing solenoids 12A & 12B causes the valve to shift and supply pressure to port 2 while exhausting pressure from port 4, thus, causing the cylinder to retract. Turning all the solenoids off allows the strong return springs to shift the redundant valves back to the center position, which blocks all ports. This traps any downstream pressure in the cylinder and holds it in its current position (see below on the right, image of valve de-energized trapping pressure). Each of the mid-position feedback sensors provide a voltage output when the valve is in the center, safe position, but no voltage output when the valve internals are shifted out of the center position. This provides a detectable center position for both sets of valve internals.
14
EXHAUST
Ground
Common - 0 VDC
Valve De-energized
Port 4
12 A
12
Power 24 VDC
Valve Faulted Side B, RIght
Port 4
1
Solenoids 14A &14B Energized Port 4 Presurized
Sensor A 0 VDC
5
2
4
3
Ground
Port 2
Sensor A + 24 VDC
2
INLET
Ground
Common - 0 VDC
12 A
Sensing Midpoint
Sensor B 4 + 24 VDC
5 3
14 A
14
Port 4 2
1 3
4
Port 2
Valve Faulted Side B, Left
14 B
12 B EXHAUST
INLET
14 A
12
12 A
Power 24 VDC
Port 4
1
Solenoids 12A & 12B Energized Port 2 Presurized
Sensor A 0 VDC
2
5 3
4
Sensor B 0 VDC Ground
Common 0 VDC
Trapped Pressure Release: In order to perform machine maintenance, after stopping the machine and performing lockout/tagout, pressure trapped in the cylinder by the CROSSCHECKTM valve can be released (exhausted) by the two manuallyoperated 2-way valves that are provided in the CROSSCHECKTM valve subbase - one each per valve outlet port. This provides a way to slowly lower the cylinder to its lowest position. NOTE: Operating the manual trapped pressure release valves will cause movement of the cylinder. Use caution to avoid any hazards associated with this movement. 14
2
Port 2
4
1 3
Sensing Midpoint
14 B
12 B
12
EXHAUST
Monitoring: External monitoring of the CROSSCHECKTM mid-position sensors must be performed by an external monitoring system. Such a monitoring system must be capable of inhibiting the operation of the valve. The safety control system must de-energize 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 valve center position before allowing an attempt to re-energize the valve. Valve reset is accomplished by de-energizing all of the valve’s solenoids. Reset of the safety control system should not occur unless the valve has fully returned to its center position (both sets of internals). The output voltage of the sensors, when switched on (center position), equals approximately the voltage supplied to the sensors by the safety controller. For example, 24 volts DC In = 24 volts DC Out, etc.
2
1 14 B
12 B EXHAUST
Common 0 VDC
Power + 24 VDC
Sensing Midpoint
Sensor B 0 VDC
INLET
14 A
12 A
Power + 24 VDC
Port 4
1 Sensor A + 24 VDC 2
Valve De-energized Trapping Pressure
© 2017, ROSS CONTROLS®. All Rights Reserved.
5 3 Common - 0 VDC
Sensor B 4 + 24 VDC Ground
CROSSCHECKTM CC4 Series Control Reliable Double Valves
Operation Overview
The CROSSCHECKTM CC4 Series double valves are redundant 4-ported, 3-position (4/3) closed-center pneumatic safety valves that are designed to meet the needs and requirements of safe cylinder control and load-holding applications for machinery with pneumatic controls. Typically, these valves are implemented to meet the Category 4 and/or Performance Level e requirements of a machine’s (or system’s) safety circuit as determined by a risk assessment of the hazards and tasks required of employees that interact with the machine (system). The valve is constructed with tight-sealing, dirttolerant poppet-type internals. The valve also has an integrated trapped pressure release system. After stopping a cylinder and performing lockout/tagout, trapped pressure can be released by way of manually-operated 2-way valves located at each end of the valve’s sub-base – one each per valve outlet port. The CROSSCHECKTM CC4 Series valve is designed to control the direction of air flow into and out of a double-acting cylinder or other pneumatic actuator in order to drive the 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 motion (load holding). Thus, reducing the potential hazard of unexpected cylinder motion during employee access for production-related tasks and/or minor servicing. Turning off all solenoids on the 4/3 CROSSCHECKTM valve returns the valve to the center position in order to stop the cylinder motion - this also allows jogging of the cylinder. However, the CROSSCHECKTM CC4 Series valve offers this function with the required level of control expected of the machine’s (system’s} safety control system up to Category 4, PL e. Such a control system must be capable of inhibiting further operation of the valve in the event of a fault within the valve. The safety function of the CROSSCHECKTM CC4 Series valve is to block further supply of 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 valve is shut off or a fault occurs within the valve. NOTE: The CROSSCHECKTM valve cannot prevent loss of pneumatic energy (compressed air) from downstream of the valve that may occur through leaks in pipe or tube fittings, broken piping or tubing, cylinder rod seals, cylinder piston seals, or other control valves. The CROSSCHECKTM CC4 Series valves are designed for external monitoring for safe, redundant operation of the valves. The CROSSCHECKTM valves are constructed of redundant, poppet type valves, and have an overall function of a double solenoid-pilot-operated, spring-centered valve. Each single valve in the CROSSCHECKTM is equipped with a Hall-effect mid-position sensor. Monitoring both of these sensors on each actuation and de-actuation of the CROSSCHECKTM valve provides a diagnostic coverage of 99%. Monitoring of these sensors must be performed by an external monitoring system that is capable of inhibiting the operation of the valve. The safety control system must de-energize 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 attempt to re-energize the valve. When a fault occurs, valve reset is accomplished by de-energizing all of the valve’s solenoids. Valve Dimensions – inches (mm)
Port Size 1/4 & 3/8 Trapped Pressure Release
4.15 (105.4)
Trapped Pressure Release 5.11 (129.7)
4.49 (114.1)
5.72 (145.3)
12.37 (314.2) 3.41 (85.6)
4.10 (104.1) 0.60 (15.2)
4.51 (114.5) 6.18 (157.0)
1.23 (31.2)
External Pilot Supply 1/4
4.60 (116.7)
0.60 (15.2)
Port Size 1/2 & 3/4
Trapped Pressure Release
5.60 (142.2)
Trapped Pressure Release
4.87 (123.7)
4.93 (125.3)
6.84 (171.1)
0.91 (23.0)
6.20 (157.6) 1.35 (34.3)
2.82 (71.5)
4.33 (110.0) 9.36 (237.7)
1.02 (25.9) 0.60 (15.2)
5.80 (147.3)
1.80 (45.7)
Pilot Valve 14 A
13.01 (330.5) 3.55 (90.2)
5.2 (132.1) 5.96 (151.4) 7.73 (196.3) 9.24 (234.8) External Pilot Supply 1/4
Pilot Valve 12 B
Ext Pi
Trapped Pressure Release Valve
PORT 4
Valve Schematic
PORT 1
PORT 3 Trapped Pressure Release Valve
PORT 2
Pilot Valve 12 A
Pilot Valve 14 B
www.rosscontrols.com
3
CROSSCHECKTM CC4 Series Control Reliable Double Valves A
1 2
5
2
4
C
B
1
1
4
5
2
3
3
Accessories
5
4 Valve Receptacle Pinouts - M12
3
A & B - Solenoids C - Sensor
B
Valve Wiring Diagram
1
4 5
2
+ +
SOL 12A
+ -
SOL 14A
+ -
SOL 12B
SOL 14B
POWER COMMON SENSOR A SENSOR B GROUND
1
3
4
1
3
2
2
A
4 5
5
3
C
Wiring Kits Wiring Kit
Description
Kit Number
M12 System Cables
Cords with female, 5-pin, straight, A-coded connector on one end, flying leads on the opposite end.
2642K77
Number Cord Length of Cords meters (feet)
1 2
3
5 (16.4)
5 3
4
Wire Colors 1 Brown 2 White 3 Blue 4 Black 5 Grey
Silencers Model Number
Port Size
Thread Type
NPT Threads
BSPT Threads
Avg. CV
1/4
Male
5500A2003
D5500A2003
3/8
Male
5500A3013
D5500A3013
1/2
Male
5500A4003
3/4
Male
5500A5013
Dimensions inches (mm) B
2.1
0.9 (21)
2.2 (55)
0.1 (0.1)
2.7
0.9 (21)
2.2 (55)
0.1 (0.1)
D5500A4003
4.7
1.3 (32)
3.6 (92)
0.2 (0.1)
D5500A5013
5.1
1.3 (32)
3.6 (92)
0.2 (0.1)
Pressure Range: 0 to 300 psig (0 to 20.7 bar) maximum.
A
B
Flow Media: Filtered air.
FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS:
• • • • • • • •
Weight lb (kg)
A
Your local ROSS distributor is:
Base Mounted Valves and Sub-Bases Line Mounted Valves Manual & Mechanical Valves Flow Control Products Air Preparation Products (F-R-L’s) Safety-Related Products ROSS/FLEX® Solution ROSS Integrated Systems
WARRANTY, CAUTIONS and WARNINGS Standard ROSS warranty, cautions and warnings apply, available upon request or at www.rosscontrols.com. ROSS CONTROLS ROSS EUROPA GmbH ROSS ASIA K.K. ROSS UK Ltd. ROSS SOUTH AMERICA Ltda. ROSS CONTROLS INDIA Pvt. Ltd. ROSS CONTROLS (CHINA) Ltd. ROSS FRANCE SAS ROSS CANADA
USA Germany Japan UK Brazil India China France Canada
Tel: 1-248-764-1800 Tel: 49-6103-7597-0 Tel: 81-42-778-7251 Tel: 44-1543-671495 Tel: 55-11-4335-2200 Tel: 91-44-2624-9040 Tel: 86-21-6915-7961 Tel: 33-1-49-45-65-65 Tel: 1-416-251-7677 (416-251-ROSS)
web site: www.rosscontrols.com web site: www.rosseuropa.com web site: www.rossasia.co.jp web site: www.rossuk.co.uk email: [email protected] email: [email protected] web site: www: rosscontrolschina.com web site: www.rossfrance.com web site: www.rosscanada.com
© 2017 ROSS CONTROLS®. All Rights Reserved.
Form NPS067
(6077170 CANADA INC. AN INDEPENDENT REPRESENTATIVE)
Printed in the U.S.A. – Rev. 10/17 Content subject to change.
352'8&7'$7$6+((7,1)250$7,21
CROSSCHECKTM CC4 Series Control Reliable Double Valves Safe Cylinder Stop and Load Holding Valve Designed for External Monitoring
up to CAT 4, PL e (certification pending)
Port Size 1/4 thru 3/4 ROSS’ new CROSSCHECKTM CC4 Series Safety directional valve is a redundant, externally monitored 4-ported, 3-position (closed center) pneumatic valve for Category 4, PL e applications, where stopping and holding a cylinder is necessary for safe operator access during production-related tasks. The valve is constructed with tight-sealing, dirt-tolerant poppet-type valve internals. Features & Benefits: • Closed Center Valve Function - allows full control of double-acting cylinders, including jog and load-holding functions • Redundant control with position feedback - can achieve Category 4, PL e, when used with proper safety controls • Designed for external monitoring - allows full safety control and feedback monitoring of cylinder control circuit • Mid-position sensing - for detection of safe, closed center position • ROSS poppet technology - fast, reliable, dirt-tolerant, face-sealing, low friction • LED indicators on solenoids - aids troubleshooting
HOW TO ORDER (Choose your options (in red) to configure your valve model number.)
CC4 Series Pressure Release Manual M Valve Only X
M
2
2
Basic Size 0 2 2 4 Basic Base Port Size Size Inlet Outlet 1/4 1/4 2 0 3/8 3/8 3 4 1/2 1/2 2 3/4 3/4 5 Valve Only (No Base) X
G
A Voltage 24 volts DC A Thread BSPP G NPT N Valve Only X
E
X
S
Communication None X Monitoring External E
4
A
2
Simplified 14B Schematic 14A
12B 12A 1
Revision Level
3
Pin Configuration Standard
S
Port Size
CV
Basic
Inlet Outlet Exhaust Size
1-2 1-4 2-3 4-3
Weight lb (Kg)
1/4
1/4
1/4
0
1
1
0.8 0.8 11.2 (5.1)
3/8
3/8
3/8
0
1
1
0.8 0.8 11.2 (5.1)
1/2
1/2
1/2
2
1.9
2
2
1.9 18.3 (8.3)
3/4
3/4
3/4
2
1.9
2
2
1.9 18.3 (8.3)
APPLICATIONS: Category 4 applications - e.g., cylinder stop & load holding applications. The CROSSCHECKTM CC4 Series valve is designed to be controlled by a safety controller or safety relay with dual channel outputs and the capability of monitoring the mid-position feedback sensors. The valve is a redundant valve and is driven by 4 solenoid pilot valves - two for extending and two for retracting.
Standard Specifications Construction: Redundant dual 4/3 closed center, poppets. Mounting Type: Sub-base mounted. Pilot Solenoid: Version as per VDE 0580. Rated for continuous duty. Enclosure rating according to DIN 400 50 IP 65. Standard Voltages: 24 volts DC. Pilot Solenoids Power Consumption (each solenoid): 3.5 watts. Electrical Connections: Three 5-pin, M12 connectors. Ambient Temperature: 40° to 140°F (+4°C to 60°C). Medium Temperature: 40° to 176°F (+4°C to 80°C). Flow Media: Compressed, filtered air according to ISO 8573-1:2010 [7:4:4].
Inlet Pressure: With Internal Pilot Supply: 60 to 120 psig (4 to 8 bar). With External Pilot Supply: 0 to 120 psig (0 to 8 bar). Pilot Supply Pressure: 60 to 120 psig (4 to 8 bar). Must be equal to or greater than inlet pressure. Static Pressure: 0 to 150 psig (0 to 10 bar). Mounting Orientation: Any, but horizontally with solenoids on top is preferred. Monitoring: Dynamic, cyclical, external with customer supplied equipment. Monitoring should check state of both valve mid-position sensors with any and all changes in state of valve control signals. Functional Safety Data: Pending.
This valve is not designed for controlling clutch/brake mechanisms on mechanical power presses, see DM2® Series D valves for mechanical power press applications.
5266 CONTROLS®
www.rosscontrols.com
CROSSCHECKTM CC4 Series Control Reliable Double Valves VALVE OPERATION
Abnormal Operation: When energizing, if both sets of valve internals do not shift synchronously (either on or off), the CROSSCHECKTM valve will block all ports. While in this fault condition, the valve cannot further pressurize or exhaust the cylinder lines. Also, as long as the fault condition exists, there will be a voltage output from the valve internals that did not shift from center, but there will not be an output from the other valve internals that did shift off center. This provides a detectable fault condition as both sensors need to agree in order to not indicate a fault.
14
4
1 3
Conditions at Start: Pressure applied to port 1, but all solenoids off. All ports (1, 2, 3, & 4) are blocked.
2
Sensing Midpoint
12
Port 2
14 B
12 B
Power + 24 VDC
EXHAUST
INLET
Operation Overview
14 A
Sensing Midpoint
1
12 A
Sensor A + 24 VDC 2
Port 2
Sensor B 4 + 24 VDC
5
Port 4
14 B
12 B
3
INLET
Sensing Midpoint
1 EXHAUST
INLET
Sensor A + 24 VDC 2
Sensor B 4 + 24 VDC
5 3
14 A
12 A
Ground
Common - 0 VDC
Port 4
Valve Faulted Side A, Left
14 B
12 B
14
EXHAUST
2
1 3
INLET
12 A
4
14 A
1 3
2
14 A
14 B
12 B
12
EXHAUST
INLET
Power + 24 VDC
Port 2
Port 2
14 B
12 B
2 12
Valve Faulted Side A, RIght
Sensing Midpoint
4
Port 2
1 3
Port 4
14
Sensing Midpoint
12 A
4
14 A
Normal Operation: Energizing both solenoids 14A & 14B causes the valve to shift and supply pressure to port 4 while exhausting pressure from port 2, thus, extending the cylinder. Conversely, energizing solenoids 12A & 12B causes the valve to shift and supply pressure to port 2 while exhausting pressure from port 4, thus, causing the cylinder to retract. Turning all the solenoids off allows the strong return springs to shift the redundant valves back to the center position, which blocks all ports. This traps any downstream pressure in the cylinder and holds it in its current position (see below on the right, image of valve de-energized trapping pressure). Each of the mid-position feedback sensors provide a voltage output when the valve is in the center, safe position, but no voltage output when the valve internals are shifted out of the center position. This provides a detectable center position for both sets of valve internals.
14
EXHAUST
Ground
Common - 0 VDC
Valve De-energized
Port 4
12 A
12
Power 24 VDC
Valve Faulted Side B, RIght
Port 4
1
Solenoids 14A &14B Energized Port 4 Presurized
Sensor A 0 VDC
5
2
4
3
Ground
Port 2
Sensor A + 24 VDC
2
INLET
Ground
Common - 0 VDC
12 A
Sensing Midpoint
Sensor B 4 + 24 VDC
5 3
14 A
14
Port 4 2
1 3
4
Port 2
Valve Faulted Side B, Left
14 B
12 B EXHAUST
INLET
14 A
12
12 A
Power 24 VDC
Port 4
1
Solenoids 12A & 12B Energized Port 2 Presurized
Sensor A 0 VDC
2
5 3
4
Sensor B 0 VDC Ground
Common 0 VDC
Trapped Pressure Release: In order to perform machine maintenance, after stopping the machine and performing lockout/tagout, pressure trapped in the cylinder by the CROSSCHECKTM valve can be released (exhausted) by the two manuallyoperated 2-way valves that are provided in the CROSSCHECKTM valve subbase - one each per valve outlet port. This provides a way to slowly lower the cylinder to its lowest position. NOTE: Operating the manual trapped pressure release valves will cause movement of the cylinder. Use caution to avoid any hazards associated with this movement. 14
2
Port 2
4
1 3
Sensing Midpoint
14 B
12 B
12
EXHAUST
Monitoring: External monitoring of the CROSSCHECKTM mid-position sensors must be performed by an external monitoring system. Such a monitoring system must be capable of inhibiting the operation of the valve. The safety control system must de-energize 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 valve center position before allowing an attempt to re-energize the valve. Valve reset is accomplished by de-energizing all of the valve’s solenoids. Reset of the safety control system should not occur unless the valve has fully returned to its center position (both sets of internals). The output voltage of the sensors, when switched on (center position), equals approximately the voltage supplied to the sensors by the safety controller. For example, 24 volts DC In = 24 volts DC Out, etc.
2
1 14 B
12 B EXHAUST
Common 0 VDC
Power + 24 VDC
Sensing Midpoint
Sensor B 0 VDC
INLET
14 A
12 A
Power + 24 VDC
Port 4
1 Sensor A + 24 VDC 2
Valve De-energized Trapping Pressure
© 2017, ROSS CONTROLS®. All Rights Reserved.
5 3 Common - 0 VDC
Sensor B 4 + 24 VDC Ground
CROSSCHECKTM CC4 Series Control Reliable Double Valves
Operation Overview
The CROSSCHECKTM CC4 Series double valves are redundant 4-ported, 3-position (4/3) closed-center pneumatic safety valves that are designed to meet the needs and requirements of safe cylinder control and load-holding applications for machinery with pneumatic controls. Typically, these valves are implemented to meet the Category 4 and/or Performance Level e requirements of a machine’s (or system’s) safety circuit as determined by a risk assessment of the hazards and tasks required of employees that interact with the machine (system). The valve is constructed with tight-sealing, dirttolerant poppet-type internals. The valve also has an integrated trapped pressure release system. After stopping a cylinder and performing lockout/tagout, trapped pressure can be released by way of manually-operated 2-way valves located at each end of the valve’s sub-base – one each per valve outlet port. The CROSSCHECKTM CC4 Series valve is designed to control the direction of air flow into and out of a double-acting cylinder or other pneumatic actuator in order to drive the 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 motion (load holding). Thus, reducing the potential hazard of unexpected cylinder motion during employee access for production-related tasks and/or minor servicing. Turning off all solenoids on the 4/3 CROSSCHECKTM valve returns the valve to the center position in order to stop the cylinder motion - this also allows jogging of the cylinder. However, the CROSSCHECKTM CC4 Series valve offers this function with the required level of control expected of the machine’s (system’s} safety control system up to Category 4, PL e. Such a control system must be capable of inhibiting further operation of the valve in the event of a fault within the valve. The safety function of the CROSSCHECKTM CC4 Series valve is to block further supply of 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 valve is shut off or a fault occurs within the valve. NOTE: The CROSSCHECKTM valve cannot prevent loss of pneumatic energy (compressed air) from downstream of the valve that may occur through leaks in pipe or tube fittings, broken piping or tubing, cylinder rod seals, cylinder piston seals, or other control valves. The CROSSCHECKTM CC4 Series valves are designed for external monitoring for safe, redundant operation of the valves. The CROSSCHECKTM valves are constructed of redundant, poppet type valves, and have an overall function of a double solenoid-pilot-operated, spring-centered valve. Each single valve in the CROSSCHECKTM is equipped with a Hall-effect mid-position sensor. Monitoring both of these sensors on each actuation and de-actuation of the CROSSCHECKTM valve provides a diagnostic coverage of 99%. Monitoring of these sensors must be performed by an external monitoring system that is capable of inhibiting the operation of the valve. The safety control system must de-energize 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 attempt to re-energize the valve. When a fault occurs, valve reset is accomplished by de-energizing all of the valve’s solenoids. Valve Dimensions – inches (mm)
Port Size 1/4 & 3/8 Trapped Pressure Release
4.15 (105.4)
Trapped Pressure Release 5.11 (129.7)
4.49 (114.1)
5.72 (145.3)
12.37 (314.2) 3.41 (85.6)
4.10 (104.1) 0.60 (15.2)
4.51 (114.5) 6.18 (157.0)
1.23 (31.2)
External Pilot Supply 1/4
4.60 (116.7)
0.60 (15.2)
Port Size 1/2 & 3/4
Trapped Pressure Release
5.60 (142.2)
Trapped Pressure Release
4.87 (123.7)
4.93 (125.3)
6.84 (171.1)
0.91 (23.0)
6.20 (157.6) 1.35 (34.3)
2.82 (71.5)
4.33 (110.0) 9.36 (237.7)
1.02 (25.9) 0.60 (15.2)
5.80 (147.3)
1.80 (45.7)
Pilot Valve 14 A
13.01 (330.5) 3.55 (90.2)
5.2 (132.1) 5.96 (151.4) 7.73 (196.3) 9.24 (234.8) External Pilot Supply 1/4
Pilot Valve 12 B
Ext Pi
Trapped Pressure Release Valve
PORT 4
Valve Schematic
PORT 1
PORT 3 Trapped Pressure Release Valve
PORT 2
Pilot Valve 12 A
Pilot Valve 14 B
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CROSSCHECKTM CC4 Series Control Reliable Double Valves A
1 2
5
2
4
C
B
1
1
4
5
2
3
3
Accessories
5
4 Valve Receptacle Pinouts - M12
3
A & B - Solenoids C - Sensor
B
Valve Wiring Diagram
1
4 5
2
+ +
SOL 12A
+ -
SOL 14A
+ -
SOL 12B
SOL 14B
POWER COMMON SENSOR A SENSOR B GROUND
1
3
4
1
3
2
2
A
4 5
5
3
C
Wiring Kits Wiring Kit
Description
Kit Number
M12 System Cables
Cords with female, 5-pin, straight, A-coded connector on one end, flying leads on the opposite end.
2642K77
Number Cord Length of Cords meters (feet)
1 2
3
5 (16.4)
5 3
4
Wire Colors 1 Brown 2 White 3 Blue 4 Black 5 Grey
Silencers Model Number
Port Size
Thread Type
NPT Threads
BSPT Threads
Avg. CV
1/4
Male
5500A2003
D5500A2003
3/8
Male
5500A3013
D5500A3013
1/2
Male
5500A4003
3/4
Male
5500A5013
Dimensions inches (mm) B
2.1
0.9 (21)
2.2 (55)
0.1 (0.1)
2.7
0.9 (21)
2.2 (55)
0.1 (0.1)
D5500A4003
4.7
1.3 (32)
3.6 (92)
0.2 (0.1)
D5500A5013
5.1
1.3 (32)
3.6 (92)
0.2 (0.1)
Pressure Range: 0 to 300 psig (0 to 20.7 bar) maximum.
A
B
Flow Media: Filtered air.
FLUID POWER PRODUCTS FOR PNEUMATIC SOLUTIONS:
• • • • • • • •
Weight lb (kg)
A
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