ROSS CC4 Series Safe Control and Load Holding Double Valve Interactive 3D Product Demonstration PDF

CC4 Series Features and Technical Highlights

Redundant Control with CrossCheck Technology

The CC4 Series achieves Category 4, PL e per ISO 13849-1:2015 and SIL 3 per IEC 62061:2005 through ROSS CrossCheck technology, which employs fully redundant internal control circuits. Both circuits must respond simultaneously to a command signal; if one circuit fails to change state within the 150-millisecond discordance window, the valve locks in the safe position to protect the operator and machine. Position feedback is provided via magnetic proximity sensors (PNP type) mounted to detect the mid-position of the spool, confirming that both poppets have returned to their safe closed-center configuration after a stop command.

Poppet Type Design for Reliable Performance

The CC4 Series uses ROSS poppet valve technology, a design philosophy that delivers fast, repeatable response times with exceptional dirt tolerance. Unlike spool valves that rely on close-clearance fits that can be compromised by contamination, poppet valves use face-sealing elements made from Acetal and Stainless Steel with Buna-N seals that close positively under spring force. The result is a valve that maintains reliable performance across millions of cycles without degradation in sealing performance, even in industrial environments with compressed air quality that does not meet the highest cleanliness standards.

Mid-Position Sensing and External Monitoring

Integrated magnetic proximity sensors (PNP type) detect the closed-center mid-position of the valve, confirming that both poppet circuits have returned to the safe state after a stop command. The CC4 Series is designed for dynamic, cyclical, external monitoring using customer-supplied safety monitoring equipment such as a safety PLC or safety relay. This monitoring architecture requires the machine control system to periodically test the valve by commanding it to its safe state and confirming via the sensor signals that it has responded correctly, satisfying the diagnostic coverage requirements for Category 4, PL e.

Trapped Pressure Relief and LED Indicators

The CC4 Series includes a manual trapped pressure relief function, allowing maintenance technicians to safely relieve any residual pressure trapped in the actuator circuit before servicing the machine. This feature supports compliance with OSHA 1910.147 lockout/tagout requirements and EN 1037 prevention of unexpected startup. Integral LED indicators on each solenoid provide immediate visual feedback on solenoid energization status, simplifying troubleshooting and commissioning without requiring additional instrumentation.

Technical Specifications and Performance Data

Operating Parameters and Pressure Ratings

• Function: 4/3 safety directional valve, closed center
• Construction: Dual Poppet design with Acetal and Stainless Steel poppets
• Actuation: Solenoid pilot operated with air assisted spring return; 4 solenoids total
• Internal Pilot Pressure Range: 60–120 psig (4–8 bar)
• External Pilot Pressure Range: 0–120 psig (0–8 bar)
• Static Pressure Rating: 0–150 psig (0–10.3 bar)
• Maximum Discordance Time: 150 milliseconds
• Ambient Temperature Range: 40–120°F (4–50°C)
• Media Temperature Range: 40–175°F (4–80°C)
• Flow Media: Compressed air per ISO 8573-1 Class 7:4:2
• Mounting: Sub-Base, any orientation (horizontal with solenoids on top preferred)
• Connection: NPT or G threaded ports
• Monitoring: Dynamic, cyclical, external with customer-supplied equipment
• Vibration tested to DIN EN 60068-2-6

Electrical Specifications

• Solenoid Voltage: 24V DC
• Power Consumption: 3.5 watts per solenoid, 4 solenoids total
• Duty Cycle: Continuous duty rated
• Enclosure Rating: IP 65 per DIN 400 50
• Electrical Connection: Two 5-pin M12 connectors

Flow Capacity and Port Sizes

• Available Port Sizes: 1/4, 3/8, 1/2, 3/4 inch NPT or G
• Flow Cv for 1/4 and 3/8 port sizes: 0.9 (900 Nl/min) ports 1 to 2
• Flow Cv for 1/2 and 3/4 port sizes: 1.7 (1700 Nl/min) ports 1 to 2
• Weight for 1/4 and 3/8 port sizes: 11.2 lb (5.1 kg)
• Weight for 1/2 and 3/4 port sizes: 18.3 lb (8.3 kg)
• Body Material: Cast Aluminum
• Poppet Material: Acetal and Stainless Steel
• Seal Material: Buna-N

Functional Safety Data

• Safety Category: Category 4 per ISO 13849-1:2015
• Performance Level: PL e per ISO 13849-1:2015
• Safety Integrity Level: SIL 3 per IEC 62061:2005
• B10D (Dangerous Failure Cycles): 10,000,000
• PFHD (Probability of Dangerous Failure per Hour): 1.62 × 10⁻⁸
• MTTFD (Mean Time to Dangerous Failure): 151 years (nop: 662,400 operations/year)
• SISTEMA Library: Available for use with SISTEMA safety calculation software

Applications and Industries

Automotive and General Manufacturing

The CC4 Series is widely applied in automotive assembly and general manufacturing environments where pneumatic cylinders must be controlled safely in automated processes. Common applications include robotic welding fixture clamping, body panel transfer systems, stamping die cushion control, and material handling automation where a mid-position stop is required to hold a load safely without motion. The valve's Category 4, PL e rating makes it suitable for guarding systems where a single valve failure must not result in a hazardous condition, and its robust poppet design handles the high cycle rates typical of automotive production lines.

Packaging and Material Handling

In packaging and material handling equipment, the CC4 Series provides safe load-holding capability for palletizer anti-drop circuits, stretch wrapper cylinder control, and conveyor diverter actuators. When a machine guard is opened or an emergency stop is commanded, the CC4 valve traps pressure in the cylinder circuit to hold a suspended load in position, preventing a dangerous drop. The valve's closed-center function means that neither the extend nor the retract port is pressurized when the valve is in the safe state, effectively locking the actuator hydraulically in place until the machine is restarted under a controlled sequence.

Food and Beverage Processing

The CC4 Series is suitable for food and beverage processing applications where safe cylinder stop capability is required in environments that demand reliable, consistent performance. The valve's stainless steel internal components and Buna-N seals are compatible with the cleaning cycles and ambient conditions typical of food processing facilities. Applications include filling machine actuators, cap press cylinder control, labeling equipment, and conveyor gate actuators where regulatory compliance with machinery safety directives requires documented Category 4, PL e performance.

Safety Standards and Compliance

The CC4 Series is designed and tested to meet the requirements of multiple international safety standards, certifications, and directives. The functional safety architecture achieves Category 4, Performance Level e per ISO 13849-1:2015 (Safety of Machinery — Safety-Related Parts of Control Systems) and Safety Integrity Level 3 per IEC 62061:2005 (Safety of Machinery — Functional Safety of Electrical, Electronic, and Programmable Electronic Safety-Related Systems). The valve has been tested and approved by DGUV (German Social Accident Insurance) under test certificate HSM 21015, confirming its suitability for safety-related pneumatic control applications. Additional certifications include CE marking for compliance with the European Machinery Directive, EAC approval for the Eurasian market, and CSA/UL certification for North American applications. Vibration resistance is verified per DIN EN 60068-2-6. Compressed air quality requirements follow ISO 8573-1 Class 7:4:2. The valve supports machine compliance with OSHA 1910.147 (Control of Hazardous Energy — Lockout/Tagout) through its manual trapped pressure relief function, and with EN 1037 (Prevention of Unexpected Startup) through its monitoring and closed-center design.

How to Use the CC4 Series 3D Interactive PDF

Navigating the 3D Model Views

The 3D PDF includes eight pre-configured views accessible through the navigation panel within Adobe Acrobat Reader or a compatible viewer. The General View presents the complete assembled CC4 Series valve from a three-quarter perspective, allowing you to rotate, pan, and zoom freely using your mouse. Inner View 1 and Inner View 2 provide cutaway perspectives of the internal valve mechanism, revealing the dual poppet circuits, solenoid pilot passages, and spring return assemblies that would otherwise be hidden inside the cast aluminum body. Use these views to understand the physical layout before consulting the cross-sectional drawings in the CC4 Series product catalog.

Exploring Valve Operation Animations

The Turn On Left Side and Turn On Right Side animation views demonstrate what happens inside the valve when each solenoid pair is energized, showing poppet movement, pilot air flow paths, and the state of the redundant monitoring sensors. The Turn Off animation shows the spring-return sequence, illustrating how both poppet circuits return simultaneously to the closed-center safe state when the solenoids are de-energized. The Cylinder Extending and Cylinder Retracting views animate a connected actuator to show the complete system behavior, helping engineers and technicians understand the relationship between valve state and actuator position during normal operation and during a safety stop event.

Why Choose ROSS Controls

Engineering Heritage and Product Quality

ROSS Controls was founded in 1921 and has more than 100 years of experience in fluid power control technology. The company pioneered CrossCheck double valve technology, which has become the industry standard reference for redundant pneumatic safety valves in machine guarding applications worldwide. ROSS products are designed and manufactured to meet the demanding requirements of industrial automation, with rigorous internal testing protocols and third-party certifications ensuring that every CC4 Series valve delivered to a customer performs to its published safety data.

Global Support and Technical Resources

ROSS Controls provides comprehensive technical support through a global network of application engineers and distributors. Customers can reach the technical support team by phone at 1-800-GET-ROSS (1-800-438-7677) or through the ROSS Controls website at www.rosscontrols.com. Technical resources available for the CC4 Series include product catalogs, operating and installation instructions, integration guides, functional safety data sheets, SISTEMA library files for safety calculation software, DGUV and CSA/UL certificates, and 2D and 3D CAD models for machine design integration.

Download CC4 Series 3D Interactive Product Demonstration PDF

What You Will Find in This Document

• Fully navigable 3D rotating model of the complete CC4 Series double valve assembly
• Inner View 1 cutaway showing left-side poppet circuit and solenoid pilot passages
• Inner View 2 cutaway showing right-side poppet circuit and spring return assembly
• Turn On Left Side animation demonstrating solenoid energization and poppet travel
• Turn On Right Side animation demonstrating independent redundant circuit activation
• Turn Off animation showing simultaneous spring return to the closed-center safe state
• Cylinder Extending demonstration showing downstream actuator behavior during valve actuation
• Cylinder Retracting demonstration showing actuator retraction and safe stop sequence
• Multi-language support — document is available in German, French, Italian, Spanish, Russian, Portuguese, Japanese, and Chinese
• Interactive navigation controls for zoom, rotate, and pan within Adobe Acrobat Reader

Who Should Download This Document

• Safety engineers performing machinery risk assessments and safety function validation
• Controls engineers designing pneumatic safety circuits for Category 4, PL e compliance
• OEM machine builders integrating safe cylinder stop and load holding into automated equipment
• Maintenance technicians who need to understand CC4 Series valve internals before service
• Plant managers evaluating pneumatic safety solutions for regulatory compliance upgrades
• Technical sales professionals supporting customer application engineering discussions
• Engineering students and trainees learning about functional safety in pneumatic systems

Related ROSS Controls Products and Documentation

• CC4 Series Product Catalog — Comprehensive specification data, model numbering system, port size selection, dimensional drawings, and ordering information for all CC4 Series configurations
• CC4 Series Operating Instructions — Installation guidance, electrical wiring diagrams for M12 connectors, commissioning procedures, monitoring system requirements, and maintenance schedules
• CC4 Series Integration Guide — Application-specific guidance for integrating the CC4 Series into safety-rated machine control systems, including safety PLC wiring diagrams and monitoring function descriptions
• CC4 Series DGUV Certificate (HSM 21015) — Official third-party test certificate issued by the German Social Accident Insurance authority confirming Category 4, PL e compliance
• CC4 Series CSA/UL Certificate — North American safety certification documentation confirming compliance with applicable electrical safety standards for industrial control equipment
• Safe Control and Load Holding PO Check Valves — Complementary ROSS products that work with the CC4 Series to provide downstream trapped pressure relief and load holding in pneumatic cylinder circuits

Frequently Asked Questions

Q: What is the CC4 Series 3D PDF and how do I view it?

A: The CC4 Series 3D PDF is an interactive product demonstration document created by 3D Sales Technologies GmbH that contains an embedded 3D model of the CC4 Series double valve. It includes pre-configured views, cutaway animations, and cylinder operation sequences. To view the 3D content, open the file in Adobe Acrobat Reader (version 8 or later). Use the mouse to rotate, pan, and zoom the model, or click the pre-configured view buttons in the navigation panel to jump to specific perspectives.

Q: What safety functions does the CC4 Series valve perform?

A: The CC4 Series performs three primary safety functions: safe control of a pneumatic actuator, safe cylinder stop (holding the actuator in mid-position), and load holding to prevent a suspended load from dropping when a safety stop is commanded. The valve achieves these functions through its redundant dual poppet design, which uses two independent internal circuits that must both shift simultaneously for flow to occur. If either circuit fails, the valve returns to or remains in the closed-center safe state.

Q: What Performance Level and SIL rating does the CC4 achieve?

A: The CC4 Series achieves Category 4, Performance Level e (PL e) per ISO 13849-1:2015 and Safety Integrity Level 3 (SIL 3) per IEC 62061:2005. These are the highest safety ratings defined in their respective standards. The supporting functional safety data includes a B10D of 10,000,000 cycles, a PFHD of 1.62 × 10⁻⁸, and an MTTFD of 151 years based on an assumed operation rate of 662,400 cycles per year. SISTEMA library files are available to support safety calculation documentation.

Q: What is the operating pressure range for CC4 Series valves?

A: The CC4 Series supports internal pilot operation at 60–120 psig (4–8 bar), which is the standard operating mode using the supply pressure from port 1 as the pilot source. For applications with supply pressures below 60 psig, the valve can be configured for external pilot operation at 0–120 psig (0–8 bar) using a separate pilot supply. The static pressure rating of the valve is 0–150 psig (0–10.3 bar), which sets the maximum system pressure regardless of operating mode.

Q: How does the CrossCheck mid-position sensing work?

A: ROSS CrossCheck technology uses two independent internal poppet circuits that must both shift simultaneously in response to a command signal. Magnetic proximity sensors (PNP type) are mounted on the valve body to detect when both poppets have returned to the closed-center mid-position after a stop command. These sensor signals are fed to the external safety monitoring system (safety PLC or safety relay), which confirms that the valve has responded correctly within the 150-millisecond discordance window. If either sensor fails to confirm mid-position within that window, the safety system can take corrective action.

Q: What port sizes are available for the CC4 Series?

A: The CC4 Series is available in four port sizes: 1/4, 3/8, 1/2, and 3/4 inch, in either NPT or G thread forms. The 1/4 and 3/8 port size models share the same body and have a flow Cv of 0.9 (900 Nl/min, ports 1 to 2) and weigh 11.2 lb (5.1 kg). The 1/2 and 3/4 port size models share a larger body with a flow Cv of 1.7 (1700 Nl/min, ports 1 to 2) and weigh 18.3 lb (8.3 kg). Port size selection should be based on required flow capacity and actuator speed calculations.

Q: Can the CC4 Series be used for press clutch/brake applications?

A: The CC4 Series is designed for safe control and load holding of pneumatic cylinders and is not intended for press clutch/brake applications. Press clutch/brake control requires a dedicated press safety valve with specific response time, monitoring, and certification requirements for press machinery safety standards. ROSS Controls offers separate product families specifically engineered and certified for press clutch/brake control. Contact ROSS Controls at 1-800-GET-ROSS (1-800-438-7677) or visit www.rosscontrols.com to identify the correct product for press applications.

Q: What monitoring system is required for the CC4 Series?

A: The CC4 Series requires dynamic, cyclical, external monitoring using customer-supplied safety monitoring equipment. This typically means a Category 4 safety PLC or safety relay that is connected to the valve's magnetic proximity sensors (via the 5-pin M12 connectors) and to the solenoid control outputs. The monitoring system must periodically command the valve to its safe state and confirm via the sensor signals that both poppets have returned to mid-position within the 150-millisecond discordance window. The frequency of monitoring cycles must be consistent with the diagnostic coverage requirements of the overall safety function.