The CC4 Series achieves the highest safety ratings available: Category 4, Performance Level e (PL e) per ISO 13849-1:2015, and SIL 3 per IEC 62061:2021. These certifications demonstrate the valve's capability to deliver control-reliable performance in safety-critical applications where unexpected cylinder motion could pose serious hazards to personnel or equipment.

Dual Poppet Design & Construction

The valve employs ROSS poppet technology featuring fast, reliable, dirt-tolerant, face-sealing operation with low friction characteristics. Redundant poppets prevent air from being supplied to or exhausted from each outlet port, creating a fail-safe design that blocks all ports when de-energized. This dual poppet construction uses acetal and stainless steel materials with Buna-N seals, housed in a cast aluminum valve body designed for durability in industrial environments.

Mid-Position Sensing Technology

The CC4 Series incorporates mid-position sensing using magnetic proximity sensors (PNP type) for detection of the closed center position. These sensors provide essential feedback to external safety control systems, enabling dynamic, cyclical monitoring that verifies both valve elements are in their safe, neutral position. This position feedback is critical for achieving Category 4, PL e performance when integrated with proper safety controls.

External Monitoring Capabilities

External monitoring must be performed by a customer-supplied safety control system capable of checking the state of both valve mid-position sensors with any and all changes in valve control signals. The monitoring system must be capable of inhibiting further valve operation in the event of a fault and preventing valve reset until both valve elements have returned to center position. This external monitoring approach provides diagnostic coverage of 99% when properly implemented.

Port Sizes & Flow Ratings

The catalog details four available port configurations with corresponding flow capacities:

Port Size 1/4" x 1/4": Flow ratings of 0.9 Cv (900 Nl/min) for ports 1-2 and 1-4, with 0.7 Cv (700 Nl/min) for port 2-3 and 0.6 Cv (600 Nl/min) for port 4-3. Unit weight approximately 11.2 lb (5.1 kg).

Port Size 3/8" x 3/8": Enhanced flow capacity for higher volume applications with similar redundant control features.

Port Size 1/2" x 1/2": Flow ratings of 1.7 Cv (1700 Nl/min) for ports 1-2 and 1.8 Cv (1800 Nl/min) for ports 2-3, supporting larger cylinder applications.

Port Size 3/4" x 3/4": Maximum flow capacity for demanding applications requiring substantial air volume.

Electrical Specifications

The CC4 Series operates on 24 VDC with power consumption of 3.5 watts per solenoid. Each valve utilizes four solenoids total—two for extending and two for retracting—in a solenoid pilot-operated configuration with air-assisted spring return. The valves feature two 5-pin M12 connectors meeting IEC 61076-2-101 standards with A-coded configuration. LED indicators on each solenoid aid troubleshooting and provide visual confirmation of energization status.

Safety Certifications & Compliance

The CC4 Series catalog provides detailed certification documentation demonstrating compliance with international safety standards and regulations.

Category 4, PL e Performance Level

Certified to Category 4, Performance Level e per ISO 13849-1:2015, the CC4 Series represents the highest achievable performance level for safety-related parts of control systems. This certification indicates the valve has been designed with redundant channels, diagnostic coverage, and resistance to common cause failures. The Category 4 architecture means a single fault will not lead to loss of the safety function, and faults are detected before the next demand on the safety system.

The valve's B10D value of 10,000,000 cycles and PFHD of 1.62 x 10⁻⁸ demonstrate exceptional reliability. The MTTFD of 151 years (with nop of 662,400 cycles) provides quantifiable data for safety system calculations.

SIL 3 Safety Integrity Level

The SIL 3 certification per IEC 62061:2021 qualifies the CC4 Series for use in safety instrumented systems requiring high levels of risk reduction. SIL 3 represents a probability of failure on demand between 10⁻³ and 10⁻² or a probability of dangerous failure per hour between 10⁻⁸ and 10⁻⁷. This certification is particularly important in industries such as manufacturing, metals processing, paper production, and assembly operations where cylinder motion hazards require robust safety measures.

DGUV & CE Certifications

The catalog documents DGUV certification (HSM 21015 – Sicherheit geprüft/tested safety) from the German Social Accident Insurance, confirming the valve meets rigorous European safety requirements. The CE marking indicates conformity with applicable European directives including the Machine Directive 2006/42/EC. Additional certifications include Declaration of Conformity and Certificate of Compliance documentation.

The valves have been tested for vibration and impact resistance per DIN EN 60068-2-6, ensuring reliable operation in demanding industrial environments.

Key Features & Valve Technology

Safe Control and Load Holding Safety Function

The primary safety function of the CC4 Series is safe cylinder control, safe cylinder stop, and load-holding. This function is accomplished by blocking further supply of pneumatic energy through the valve and blocking the exhaust of any pneumatic energy from cylinder lines downstream whenever the valve is shut off or a fault occurs. This prevents unexpected cylinder motion during employee access for production-related tasks or maintenance servicing.

When all solenoids are de-energized, the valve returns to center position, trapping pneumatic energy in the cylinder to stop and hold motion. This load-holding capability is essential for vertical cylinder applications and other situations where gravity or external forces could cause hazardous movement.

Redundant Control Architecture

The CC4 Series employs redundant control with position feedback that can achieve Category 4, PL e when used with proper safety controls. Each valve element operates independently with its own solenoid and position sensor, creating a dual-channel architecture. If both sets of valve internals do not shift synchronously during energization or de-energization, the valve automatically blocks all ports, preventing further pressurization or exhaust.

This redundant design ensures that a single mechanical failure, such as a blocked spool or damaged seal, will not result in loss of the safety function. The system detects discordance between the two valve elements and enters a safe, locked state.

Trapped Pressure Relief Systems

The catalog details manual trapped pressure relief valves integrated into the valve sub-base. Two manually-operated 2-way valves—one for each outlet port—allow controlled release of trapped pressure for maintenance purposes. This feature enables safe lowering of vertical loads or repositioning of cylinders after lockout/tagout procedures.

Important: Operating manual trapped pressure relief valves will cause cylinder movement, requiring caution to avoid hazards associated with load motion.

LED Indicators & Diagnostics

LED indicators mounted on each solenoid provide immediate visual feedback on energization status, significantly aiding troubleshooting and system diagnostics. These indicators allow maintenance personnel to quickly verify electrical signals are reaching the valve without requiring measurement equipment.

Application Solutions & Industry Use Cases

Pneumatic Cylinder Control

The CC4 Series excels in applications requiring precise directional control of double-acting cylinders with the added safety of load-holding capability. The valve controls air flow to drive cylinders forward or backward according to machine operational requirements, then traps pressure to stop and hold motion when signaled.

Turning off all solenoids returns the valve to center position, stopping cylinder motion while maintaining position. This also enables cylinder jogging or "inching" capability through momentary solenoid operation, allowing precise positioning at intermediate points rather than just fully extended or retracted positions.

Load Holding Applications

Load holding is a critical safety function in numerous industrial applications. The CC4 Series provides this function through its closed-center design that traps pressure in both cylinder chambers when de-energized. This prevents load drift on equipment such as:

• Mobile equipment: Cherry pickers, aerial work platforms, and boom lifts where operators work at height and require stable positioning
• Manufacturing presses: Cylinder-operated presses requiring controlled motion and load holding for worker safety
• Material handling: Lifting and positioning equipment where unexpected movement poses injury risks
• Assembly operations: Clamping and holding fixtures requiring reliable position maintenance

Manufacturing & Assembly Operations

In manufacturing and assembly environments, the CC4 Series provides safety solutions for various pneumatic actuation challenges. Applications include:

• Press metal forming operations where cylinder motion must be precisely controlled and stopped in safe positions during employee access. The valve's Category 4, PL e rating meets requirements for control-reliable operation in press applications when properly integrated with safety systems.
• Assembly and test equipment requiring safe cylinder control for clamping, positioning, and actuating mechanisms. The valve's load-holding capability ensures stable holding of assemblies during processing.
• Metals industry applications in harsh environments of aluminum smelters and steel processing facilities where reliability and safety are paramount. ROSS Controls' global network supports these demanding applications with proven solutions.
• Paper industry applications including winders, take-ups, roll handling systems, slitters, and embossers where safe cylinder control prevents injuries and equipment damage.

Safety-Critical Environments

The CC4 Series meets stringent requirements for safety-critical pneumatic control in applications where:

• Risk assessment determines Performance Level d or e is required per ISO 13849-1
• SIL 2 or SIL 3 capability is specified for safety instrumented functions
• Regulatory compliance requires control-reliable pneumatic safety systems
• Machine guarding standards mandate redundant control with monitoring

Note: These valves are not designed for controlling clutch/brake mechanisms on mechanical power presses. Press control applications require specialized double valve solutions designed specifically for that purpose.

Model Configuration & Ordering Information

Available Port Configurations

The catalog includes a comprehensive model number configurator for specifying exact valve configurations. Model numbers follow the format: CC4M[port size][thread type][monitoring][communication][pressure relief][revision] 

Example model numbers include:

• CC4M22NAEXSA: 1/4" NPT ports with external monitoring
• CC4M23NAEXSA: 3/8" NPT ports with external monitoring
• CC4M23GAEXSA: 3/8" G-thread ports with external monitoring
• CC4M44NAEXSA: 1/2" NPT ports with external monitoring
• CC4M45NAEXSA: 3/4" NPT ports with external monitoring

Wiring Diagrams & Connectivity

Detailed wiring diagrams and valve receptacle arrangements are provided showing connections for:

Connector A & B (Solenoids): 5-pin M12 connections for solenoid power supply

• Pin 1 (Brown): Power +24 VDC
• Pin 2 (White): Not used
• Pin 3 (Blue): Common 0 VDC
• Pin 4 (Black): Not used
• Pin 5 (Gray): Not used

Connector C (Sensors): 5-pin M12 connection for position sensors

• Pin 1 (Brown): Sensor A +24 VDC output
• Pin 2 (White): Sensor B +24 VDC output
• Pin 3 (Blue): Ground
• Pin 4 (Black): Not used
• Pin 5 (Gray): Not used

The output voltage of sensors when switched on (center position) equals approximately the voltage supplied by the safety controller.

Operating Conditions & Specifications

Temperature Ranges:  

• Ambient: 40° to 120°F (4° to 50°C)
• Media: 40° to 175°F (4° to 80°C)

Pressure Specifications:  

• Operating pressure with internal pilot: 60 to 120 psig (4 to 8 bar)
• Operating pressure with external pilot: 0 to 120 psig (0 to 8 bar)
• External pilot supply: 60 to 120 psig (4 to 8 bar) - must equal or exceed inlet pressure
• Static pressure: 0 to 150 psig (0 to 10.3 bar)

Flow Media: Compressed air per ISO 8573-1 Class 7:4:2

Mounting: Sub-base mounting with any orientation; horizontal with solenoids on top preferred

Enclosure Rating: IP 65 per DIN 40050

Integration & Installation Resources

SISTEMA Library & Safety Calculations

SISTEMA library files are available for download from rosscontrols.com, enabling safety engineers to incorporate CC4 Series valve data into their safety function calculations. The Safety Integrity Software Tool for the Evaluation of Machine Applications (SISTEMA) validates that safety functions achieve required Performance Levels per ISO 13849-1.

The catalog provides functional safety data required for SISTEMA calculations:

• Category: CAT 4
• Performance Level: PL e
• B10D: 10,000,000 cycles
• PFHD: 1.62 x 10⁻⁸
• MTTFD: 151 years (nop: 662,400)

Integration Guide

An Integration Guide for CC4 Series Double Valves is available from ROSS Controls, providing detailed information on:

• Valve operation principles and sequences
• Monitoring requirements and implementation
• Integration into customer control circuits
• Electrical interface specifications
• Troubleshooting procedures

This guide is essential for proper implementation of the CC4 Series in safety-critical applications.

Accessories & Support Components

The catalog documents compatible accessories including:

Prewired Electrical Connectors: Pre-assembled cable kits with M12 connectors and flying leads, available in 5-meter (16.4-foot) lengths for simplified installation.

Exhaust Silencers: Aluminum silencers available for all port sizes (1/4", 3/8", 1/2", 3/4") with male NPT or R/Rp threads. Pressure rating 0-290 psig (0-20 bar) maximum. Flow capacities range from 2.3 Cv (2300 Nl/min) for 1/4" to 18 Cv (18,000 Nl/min) for 3/4" ports.

Maintenance & Operational Requirements

Minimum Operation Frequency: Once per month to ensure proper function

Maximum Recommended Allowable Discordance Time: 150 milliseconds between valve element movements

Monitoring Requirements: Dynamic, cyclical, external monitoring with customer-supplied equipment checking state of both valve mid-position sensors with all changes in valve control signals.

Downloadable CAD Models

CAD models are available for download, enabling integration into machine designs and documentation. These models support various CAD platforms and include accurate dimensional data for all valve configurations.

Technical Dimensions

Complete dimensional drawings are provided in the catalog for all port sizes:

• Port Sizes 1/4" & 3/8": Length 12.37" (314.2mm), Width 4.60" (116.7mm), Height 5.72" (145.3mm)
• Port Sizes 1/2" & 3/4": Length 13.61" (345.7mm), Width 5.80" (147.3mm), Height 6.84" (171.1mm)

Drawings indicate locations of solenoids, sensor connectivity, external pilot port, trapped pressure release valves, and all port connections.