Ross controls Crosscheck cc4 series Quick setup guide

ROSS CONTROLS®

www.rosscontrols.com

CrossCheCk™ CC4 series

safe Cylinder Control and stop double ValVes

integration guide

CC4 Series Valves Integration Guide

Table of Contents

Integration Guide – CC4 Safe Cylinder Control and Stop Double Valves

Page

Valve General Information

Introduction

3Pulse Testing

Stopping Times

CC4 Wiring (Pinouts) 4

Conversion to External Pilot Supply

4 - 5

Operation & Monitoring Requirements for 4/3 CC4 Series Valves

Valve Operation 6

Feedback Monitoring (General)

Actuation Fault Monitoring

8 - 9De-Actuation Fault Monitoring

Loss of Supply Pressure While Actuated

No Supply Pressure Applied Before Actuation

Valve Fault & Safety System Reset

Limitations of Load Holding Due to System Leakage

Valve Test Procedure

CC4 Validation Test Procedure for Valve Operation and External Monitoring Logic 10 - 14

Cautions, Warnings and Standard Warranty Cover

Global Locations

www.rosscontrols.com 3

CC4 Series Valves Integration Guide

Introduction

ROSS Controls offers a variety of safety valves for use in various safety functions such as safe exhaust, safe cylinder return, and

safe cylinder control/stop (load holding). This document focuses speciﬁcally on ROSS Controls’ 4/3 CC4 Series valves that are

used for safe cylinder control/stop functions and utilize magnetic proximity sensors (PNP) to provide feedback to a safety control

system for external monitoring.

Pulse Testing

In dual channel safety circuits, pulse testing is a method utilized to detect fault conditions that, otherwise, may be undetected. Pulse

testing of the solenoids is required in dual channel circuits in order to reach performance level e (PL e). However, pulse testing

of the feedback sensors is not required. Pulse testing of the solenoids will not affect the performance of the ROSS CC4 valve.

There are two methods of pulse testing outputs. The most common method is to use the native pulse testing instruction embedded

by the manufacturer in Safety PLCs and Safety Relays. The other method is to use custom programming code generated by the

user. We recommend the use of native pulse testing instructions of the respective manufacturers’ safety Safety PLCs or Safety

Relays because these instructions are ﬁxed and cannot be tampered with. These instructions typically have a pulse period (cycle)

of 400 ms to 600 ms and a pulse width of 0.4 ms to 0.8 ms. Pulse testing the outputs to the solenoids on the CC4 valve at this

frequency and duration does not affect the performance of the valve but does provide a method to monitor for the occurrence of

wiring faults in the output portion of the safety circuit controlling the valve solenoids.

Stopping Times for Safe Distance Calculations

When designing a safety circuit, the machine stopping time is a critical factor that determines the placement of guarding solutions.

When using valves for a “safe cylinder control/stop” safety function, one factor in safe distance calculations is the response time

of the valve. The faster your valve shifts, the quicker the cylinder can stop. The quicker the machine can stop, the closer your

guarding solutions may be placed to the hazardous area. This can improve overall operating efﬁciency, ergonomics, and possibly

allow the footprint of the machine to be smaller.

Unlike exhaust valves, the critical application time with blocking type valves is the parts movement time to block all ports (closing

time) when switching from the energized condition to the de-energized condition. See the chart below for speciﬁc closing time

intervals for the two sizes of CC4 valve.

Safe Distance calculations should be validated by testing.

Closing Time (time in ms from energized to all ports blocked)

Normal Response (not faulted)

Valve Basic Size From Port 2 Pressurized From Port 4 Pressurized

0 70 80

2 90 100

Faulted Response

Valve Basic Size From Port 2 Pressurized From Port 4 Pressurized

0 75 90

2 125 160

Note: Measured with supply pressure of 100 psig.

CC4 Series Valves Integration Guide

CC4 Wiring (Pinouts)

The CC4 wiring connections are made via two male M12 receptacles for the solenoids and one female M12 receptacle for the sensors.

Pinouts are shown below. The M12 receptacles are wired such that if the solenoid cables are inadvertently swapped the valve will

still operate the same as if they had not been swapped.

NOTE: The sensors must be wired with 24 volt (+) and 0 volt (-) connections in parallel with each other.

1 2

3 4

Valve Receptacle Arrangement

A & B - Solenoids

C - Sensor

IEC 61076-2-101

A CODED M12

SOL 12A

SOL 14B

SOL 14A

SOL 12B

POWER

COMMON

SENSOR A

SENSOR B

GROUND

GRAY

BLUE

BLACK

BROWN

WHITE

GRAY

BLACK

Valve Wiring Diagram

Conversion to External Pilot Supply

The CC4 Series valve comes from the factory conﬁgured for internal pilot supply, which sources pilot supply air pressure internally

from port 1 in the valve sub-base. However, the valve can be converted in the ﬁeld to operate with external pilot supply through

the X port in the valve sub-base. When this conversion to external pilot supply is made, the valve solenoid pilots will get their

supply air from a source that is independent of the supply line connected to port 1.

External pilot supply is typically used in applications where the normal supply pressure may be lower than the minimum operating

pressure of the valve (60 psig (4 bar)). While external pilot supply may be a good alternative to internal pilot supply in certain

applications, caution should be taken to avoid unsafe situations. For example, when using external pilot supply, a loss of pressure

in port 1 while the valve is actuated could cause unexpected movement. In this situation, the valves will remain actuated by pressure

from the external pilot source.This would allow both ports 2 and 4 to be exhausted, potentially causing unexpected motion. However,

this situation can be detected through the addition of an upstream pressure switch or transducer in the main supply line to port 1.

Once a fault is detected, the safety control system should turn off the outputs to all the valve solenoids. See Loss of Supply Pressure

While Actuated on page 6.

WARNING: A loss of supply pressure to the valve and cylinder could cause unexpected cylinder movement.

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CC4 Series Valves Integration Guide

In order to convert the CC4 valve to external pilot supply:

A. Shut-off and exhaust all pressure from the system and disconnect all electrical power from the valve.

B. Remove the cover from the valve (2 screws). See photo below (left).

C. Remove the valve from its sub-base (7 screws). See photo below (right).

D. In the bottom of the valve, move the small pipe plug from the innermost hole to the outermost hole (max. torque 216 in-lbs (24.4

Nm)). See images below.

E. Reinstall the valve on the sub-base (7 screws). See photo below (right).

Torque to: Port size 1/4 & 3/8: 49 in-lbs (5.5 Nm).

Port size 1/2 & 3/4: 216 in-lbs (24.4 Nm).

F. Reinstall the cover (2 screws). Torque to 25 in-lb (2.8 Nm). See photo below (left).

G. Remove the pipe plug from the X port in the sub-base.

H. Install a new pilot supply line to the X port in the sub-base. The source for this external pilot supply line should be able to supply

a minimum of 60 psig during system operation.

With Internal Pilot Supply For External Pilot Supply

Port Size 1/4 & 3/8

With Internal Pilot Supply For External Pilot Supply

Port Size 1/2 & 3/4

Set screw installed here

for INTERNAL

pilot supply.

Install set screw here

for EXTERNAL

pilot supply.

EXTERNAL port.

Install set screw here

for EXTERNAL

pilot supply.

EXTERNAL port.

Set screw installed here

for INTERNAL

pilot supply.

Cover Screws

Top View Top View - Open Cover

Valve to Base Mounting Screws

CC4 Series Valves Integration Guide

Operation & Monitoring Requirements for 4/3 CC4 Series Valves

The intent of this document is to provide guidance on how to operate

and monitor the 4/3 CC4 valve for safe operation.

A test procedure is also provided for veriﬁcation and validation of the

user’s external safety control monitoring system.

Valve Operation

The CC4 valve is a redundant, 4-port, 3-position, closed center valve. Its function is that of a 4/3, closed center, double-solenoid

pilot-operated valve. However, because the valve is redundant it has four operating solenoids: two for extending a cylinder and

two for retracting. When the valve is de-actuated, all 4 ports on the valve are closed (inlet port 1, outlet port 2, outlet port 4, &

exhaust port 3).

In order to pressurize port 2 and exhaust port 4, both the 12A and 12B solenoids must be operated simultaneously. Conversely,

in order to pressurize port 4 and exhaust port 2, both the 14A and 14B solenoids must be operated simultaneously. These pairs

of solenoids must be operated by dual channel outputs from a

safety control system.

NOTE: The 12A & 12B solenoids are physically located diagonally

opposite each other on the valve, and the 14A & 14B solenoids

are located at the other two opposite corners (diagonally).

De-actuating all of the solenoids returns the valve to the center,

all-ports-closed position in order to trap air pressure in both

cylinder lines to stop cylinder motion.

The CC4 valve is equipped with two sets of closed-center position,

double-solenoid pilot valves that are integrated as a redundant

and monitorable 4/3 closed-center-position directional valve that

can be used to extend, retract, jog, and stop a cylinder. Each set of valves has a single, bi-directional magnetic proximity sensor

that is wired as a PNP type sensor. When the valves are in the center position, the sensor outputs provide a voltage output signal

to the inputs of the safety monitoring system. When the valves are actuated, the sensors switch off. Therefore, when both of the

valves in the CC4 are in the center, de-actuated position, both sensors provide a 24 volts DC feedback signal, and when the valves

are not in the center position (actuated), the sensors both provide a 0 volts DC feedback signal.

Normal operation occurs when both sets of valve internals shift within 150 msec of any change of the solenoid signals (12A & 12B

or 14A & 14B). For example, when both the 12A & 12B solenoids are signaled to actuate, we would expect both proximity sensors

to turn off within 150 msec of the application of the solenoid signals.

In the event of a valve fault where one of the redundant valve components does not operate normally, as commanded, the valve

will perform its safety function which is to default to a condition where all ports are closed, including supply port 1, outlet port 2,

outlet port 4, and exhaust port 3. The fault should be latched in by the safety monitoring system until a reset is performed.

Failure of the valve to shift normally leads to a fault in the CC4 valve. This could happen for a variety of reasons, such as:

• Compromised piston seals

• Main valve elements experiencing a switching delay due to dirt, debris or resinous oil

• Insufﬁcient electrical signals to valve solenoids; suitable voltage not available

• Receipt of signals at solenoids not synchronous

• Pilot valves experiencing a switching delay due to damaged components, dirt, debris or resinous oil

• Excessive water build-up in the valve

Pilot Valve

12 B

Pilot Valve

14 B

Ext Pi

PORT 1

PORT 2

PORT 4

PORT 3

Trapped Pressure

Release Valve

Trapped Pressure

Release Valve

Pilot Valve

12 A

Pilot Valve

14 A

Valve Schematic

Simpliﬁed Valve Schematic

1 3

4 2

14 A

14 B

12 A

12 B

Solenoid 14B

Solenoid 12A

Solenoid 12B

Solenoid 14A

Schematics do not depict

physical location of solenoids.

www.rosscontrols.com 7

CC4 Series Valves Integration Guide

Feedback Monitoring (General)

The CC4 valve is equipped with feedback proximity sensors that must be monitored by the user’s external safety control & monitoring

system to detect fault conditions within the valve. Sensor feedback should always be opposite the solenoid actuating signals. In other

words, when the solenoids are energized, the sensor outputs should be off and when the solenoids are de-energized, the sensor

outputs should be on.

WARNING: It is possible to operate at a cycle rate that could result in non-monitored operation. To prevent exceeding this rate,

ensure that the valve is de-actuated (both sensor outputs should be on) before attempting to energize the solenoids. Likewise,

ensure that the valve is actuated (both sensor outputs should be off) before attempting to de-energize the solenoids.

NOTE: In the event of a stop signal from any safety system input, the safety system should immediately shut off the safety controller

outputs to the valve solenoids (as required by the application) regardless of the condition of the feedback sensors.

Refer to EN ISO13849-1 for Cat 3 vs Cat 4 monitoring.

Automatic RESET is not recommended by ROSS.

Valve Operation and General Feedback Monitoring Ladder Logic Example

Extend

Signal

Sensor

Safety Stop

Signal

Extend

De-actuation

Fault*

Extend Solenoids

Energized

Extend Solenoids

Energized

Sensor

< >

Sensor

BExtend Solenoids De-energized

Retract

Actuation

Fault*

< >

TON

Timer On Delay

Extend Actuation Timer

Timer Value = 150 msec

< >

TON

Timer On Delay

Extend De-actuation Timer

Timer Value = 150 msec

Sensor B

Retract

De-actuation

Fault*

Extend

Actuation

Fault*

Extend

Signal

Extend

Solenoids

Energized

Sensor A

Retract

Signal

Sensor

Safety Stop

Signal

Extend

De-actuation

Fault*

Retract Solenoids

Energized

Retract Solenoids

Energized

Sensor

< >

Sensor

BRetract Solenoids De-energized

Retract

Actuation

Fault*

Retract Solenoids

De-energized

< >

TON

Timer On Delay

Retract Actuation Timer

Timer Value = 150 msec

< >

TON

Timer On Delay

Retract De-actuation Timer

Timer Value = 150 msec

Sensor B

Retract

De-actuation

Fault*

Extend

Actuation

Fault*

Retract

Signal

Retract

Solenoids

Energized

Sensor A

E-Stop Button** Safety Stop Signal

Reset

Safety Stop

Signal

< >

General

Feedback

Fault

General

Feedback

Fault

Sensor A

Extend

Solenoids

De-energized

Retract

Solenoids

De-energized

Retract

Solenoids

Energized General Feedback Fault

Reset

< >

Extend

Solenoids

Energized

General Feedback

Fault

Sensor B

*Explained in sections below.

Extend Solenoids

De-energized

Solenoid 14A

< >

Solenoid 14B

Extend Solenoids

De-energized

Retract Solenoids

De-energized

Solenoid 12A

< >

Solenoid 12B

*Explained in sections below.

**Could be an input from any safety device, such as a light curtain.

CC4 Series Valves Integration Guide

Actuation Fault Monitoring

Actuation fault monitoring should check for actuation of both valves within 150 msec of the application of the actuation signal. After

the safety control system simultaneously applies the actuation signal to both solenoids (12A & 12B or 14A & 14B), both sensor

outputs should switch off within 150 msec. If both sensors have not changed state within the 150 msec time-frame, this should

be registered as a valve fault.

Actuation Fault Monitoring Ladder Logic Example

Reset

Sensor A < >

Sensor B

Extend Actuation Fault

Extend

Actuation Timer

Extend

Actuation Fault

Reset

Sensor A < >

Sensor B

Retract Actuation Fault

Retract

Actuation Timer

Retract

Actuation Fault

De-Actuation Fault Monitoring

De-Actuation fault monitoring should check for de-actuation of both valves within 150 msec of the removal of the actuation signal.

After the safety control system simultaneously removes the actuation signals from both solenoids (12A & 12B or 14A & 14B), both

sensor outputs should switch on within 150 msec. If both sensors have not changed state within the 150 msec timeframe, this

should be registered as a valve fault.

De-actuation Fault Monitoring Ladder Logic Example

Reset

Sensor A < >

Sensor B

Extend De-Actuation Fault

Extend

De-Actuation Timer

Extend

De-Actuation Fault

Reset

Sensor A < >

Sensor B

Retract De-Actuation Fault

Retract

De-Actuation Timer

Retract

De-Actuation Fault

Loss of Supply Pressure While Actuated

The condition of loss of supply pressure while the valve is actuated must be detected by the safety control monitoring system.

NOTE: The safety function of the CC4 valve is to close all ports when the valve is switched off and/or when the valve is in a fault

condition.

Using INTERNAL Pilot Supply (Standard conﬁguration):

When operating the CC4 valve with INTERNAL pilot pressure (supplied internally from supply port 1), loss of supply pressure

while actuated will cause both valves to de-actuate due to lack of pilot pressure; thus, causing all ports to close (trapping pressure

in both cylinder lines downstream of outlet ports 2 & 4) and also causing both sensors to switch on. Therefore, this fault can be

detected where the solenoids are energized, and one or both sensors go from off (not sensing the center, de-actuated position)

to on (sensing the center, de-actuated position). This condition should be registered as a valve fault.

NOTE: No additional ladder logic is required for Loss of Supply Pressure While Actuated because this fault is detected by the

Actuation Fault Monitoring logic.

WARNING: Valve does not close due to loss of supply pressure until the supply pressure drops below 60 psig (4 bar) which

could result in unexpected cylinder movement.

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CC4 Series Valves Integration Guide

Using EXTERNAL Pilot Supply (Optional conﬁguration):

When operating the CC4 valve with EXTERNAL pilot pressure (supplied externally from a separate source through the X port), a loss

of supply pressure in supply port 1, but not in external pilot supply port X, will allow the valves to remain actuated; thus, potentially

causing unexpected cylinder movement. This fault where both valves remain actuated while the main supply pressure is lost can

be detected through the addition of an upstream pressure switch or transducer in the main supply line to port 1. This additional

pressure switch or transducer must be monitored by the safety monitoring system to detect a fault where supply pressure in port 1

is too low. This condition should be registered as a valve fault by the safety control monitoring system, which should remove power

from all solenoids on the CC4 valve. Thus, stopping any further cylinder movement.

WARNING: When utilizing EXTERNAL pilot supply from a source that is independent of the main valve supply, loss of pressure

in the main valve supply could cause unexpected cylinder movement.

NOTE: No ladder logic example provided for additional equipment.

No Supply Pressure Applied Before Actuation

Monitoring of supply pressure may also be utilized if deemed beneﬁcial for the application but is not required (unless using external

pilot supply). If you choose to detect this condition it would require the addition of an upstream pressure switch or transducer in

the main supply line to port 1. The condition of the pressure switch or transducer should be monitored to prevent actuation of the

valve when supply pressure is insufﬁcient. However, this becomes essential when external pilot pressure is being used.

See above information on Loss of Supply Pressure While Actuated.

NOTE: No sample ladder logic provided for additional equipment.

Valve Fault & Safety System Reset

Any detected fault in the valve system should cause the safety control system to de-actuate the valve by removing power from all

solenoids. Any fault should be latched in by the safety monitoring system until a reset is performed. A reset of the safety control

system should only be possible after the valve sensors indicate that both valves in the CC4 are in the center, de-actuated position

(both sensors switched on).

Safety System Reset Ladder Logic Example

< >

Reset Button Extend Signal Sensor A Sensor BRetract Signal Reset

Limitations of Load Holding Due to System Leakage

Leakage in a safe cylinder stop/load holding application has the potential to create unexpected motion regardless of whether the

leakage occurs in the valve, hoses, connections or the cylinder. The CC4 series valves are equipped with valve position sensors for

external monitoring to meet diagnostic coverage requirements. However, position sensing does not detect leakage. The CC4 series

valves are designed to have redundant valve elements that are interconnected in such a manner that any single point of leakage within

the valve will not cause unexpected movement. Therefore, periodic leakage testing of the system may be necessary depending on

the risk assessment speciﬁc to the machine or application. If leakage is discovered, measures should be taken to eliminate the leak.

WARNING: Continued operation of the system without periodic leakage inspections can lead to unexpected movement.

Refer to steps 1 - 9 below to help identify valve/system leakage.

Step # Fault Conditions Procedures Sol

12A

Sol

12B

Sol

14A

Sol

14B

Outlet Pressure Sensor Condition Expected

Cylinder

Action

Notes Results

Port 2 Port 4 Sensor A Sensor B

NOTE: Prior to step 1 the cylinder needs to be positioned near mid-stroke.

1Momentarily energize

solenoids 12A & 12B

On then

off

On then

off Off Off Line Line Off then

Off then

Partial

retract

Energize only long enough

for a partial stroke.

2 Energize solenoid 12A On Off Off Off Line Line Off On None Fault

3 De-energize solenoid 12A Off Off Off Off Line Line On On None No fault

4 Energize solenoid 12B Off On Off Off Line Line On Off None Fault

5 De-energize solenoid 12B Off Off Off Off Line Line On On None No fault

6 Energize solenoid 14A Off Off On Off Line Line Off On None Fault

7 De-energize solenoid 14A Off Off Off Off Line Line On On None No fault

8 Energize solenoid 14B Off Off Off On Line Line On Off None Fault

9 De-energize solenoid 14B Off Off Off Off Line Line On On None No fault

Valve/System Leakage Test Procedure

Operation & Monitoring – Loss of Supply Pressure While Actuated (continued)

CC4 Series Valves Integration Guide

Step Action

Retract

Signal

Extend

Signal Sol 12A Sol 12B Sol 14A Sol 14B Port Conditions

Outlet Condition at

End of Stroke Sensor Conditions Cylinder

Action

Fault

Pass/Fail

(12A & 12B) (14A & 14B) Port 2 Port 4 Sensor A Sensor B (P/F)

1 Energize solenoids 12A & 12B ON OFF ON ON OFF OFF 1 to 2 | 4 to 3 Pressure None OFF OFF Retract No

2 De-energize solenoids 12A & 12B OFF - OFF OFF - - All closed - - ON ON Stop -

3 Energize solenoids 14A & 14B - ON - - ON ON 1 to 4 | 2 to 3 None Pressure OFF OFF Extend -

4 De-energize solenoids 14A & 14B - OFF - - OFF OFF All closed - - ON ON Stop -

5 Disconnect solenoid signal wire from solenoid 12B OFF OFF OFF OFF OFF OFF All closed None Pressure ON ON Stop No

6 Attempt to energize solenoids 12A & 12B ON - - - - - - - - - - - Yes*

7 Reconnect solenoid 12B - - - - - - - - - - - - -

8 De-energize solenoids 12A & 12B OFF - - - - - - - - - - - -

9 Reset the safety control system - - - - - - - - - - - - No

10 Disconnect solenoid signal wire from solenoid 12A OFF OFF OFF OFF OFF OFF All closed None Pressure ON ON Stop No

11 Attempt to energize solenoids 12A & 12B ON - - - - - - - - - - - Yes*

12 Reconnect solenoid 12A - - - - - - - - - - - - -

13 De-energize solenoids 12A & 12B OFF - - - - - - - - - - - -

14 Reset the safety control system - - - - - - - - - - - - No

NOTE 1: This validation test procedure should only be performed with a CC4 valve that is known to be functioning properly. If basic valve function is in question please refer to Section 8 of the Product Operating

Instructions for the Valve Test Procedure.

NOTE 2: These procedures require fault simulation. It will be necessary to induce faults electrically by disabling a different solenoid or sensor at different times. This will be most easily done by disconnecting solenoid or

sensor wires at the safety controller.

NOTE 3: Ports 2 and 4 should be connected to a cylinder with a gauge or pressure sensor teed into each line. Or, just a gauge in each outlet port, 2 and 4.

NOTE 4: Supply pressure will need to be supplied to inlet port 1.

NOTE 5: Power for the sensor board needs to be maintained throughout the entire procedure. Pins 1 and 3 must remain connected at all times during this validation test.

NOTE 6: This procedure pertains to internal pilot conguration only.

NOTE 7: “-” indicates no change from previous step.