Manifold Blanking Kit For ISO 15407, ISO 5599 & 95 Series Valves

Product Overview

The ROSS Controls Manifold Blanking Kit provides blank station plates, gaskets, and mounting bolts designed to seal unused valve positions in ISO 15407, ISO 5599, and 95 Series base-mounted valve manifold assemblies. When a manifold is specified with more stations than valves installed at system commissioning, blanking kits occupy the empty positions to prevent air loss through the unsealed station openings and to maintain manifold supply galley integrity.

Manifold blanking kits are an essential forward-planning tool for machine builders and system designers. By specifying a manifold with additional stations at initial build, and installing blanking kits in the unfilled positions, engineers retain the ability to add valve stations during later machine upgrades without replacing the manifold body. This eliminates the cost and downtime of manifold replacement when production requirements change.

Available for ISO 5599-2 W65 Series (Sizes 1, 2, and 3), ISO 5599-1 W60/W64 Series (Sizes 1, 2, and 3), ISO 15407-1 and ISO 15407-2 W66 Series (Sizes 00 and 0), SAE Series (Sizes 125, 250, and 500), and 95 Series valve manifolds, the blanking kit family provides complete coverage across the ROSS base-mounted valve product line. Each kit is a complete assembly: blank station plate, manifold sealing gasket, and appropriate mounting bolts.

For procurement specialists and design engineers managing pneumatic system lifecycle, Manifold Blanking Kits represent a low-cost investment that preserves manifold expandability and prevents the need for costly manifold replacement when production lines evolve.

Key Engineering Features

• Seals Unused Manifold Stations - The blank plate and gasket assembly seals the top surface and all port openings of an unused manifold station, preventing supply air from escaping the manifold galley and maintaining system pressure without leakage at empty positions.
• Complete Kit Supplied - Each blanking kit includes the blank station plate, the appropriate manifold-surface gasket, and the required mounting bolts, so no separate hardware needs to be sourced for installation.
• Manifold Expansion Planning - Filling reserved station positions with blanking kits at initial build allows future valve addition without manifold replacement. A machine can be upgraded from two to four valve stations, for example, by removing blanking kits and installing valves with their sub-bases.
• Full ISO and SAE Coverage - Blanking kits available for ISO 5599-2 W65, ISO 5599-1 W60/W64, ISO 15407-1/2 W66, SAE, and 95 Series manifold platforms ensure system-wide compatibility across all ROSS base-mounted valve families.
• Low Cost Per Station - At list prices from $3.50 to $56.50 per kit depending on ISO size, manifold blanking kits represent a minor incremental cost that prevents expensive manifold replacement later in the machine lifecycle.
• Standard Mounting Interface - Blank station plates match the footprint and mounting hole pattern of the corresponding valve size, maintaining the manifold assembly's structural integrity and consistent appearance.

Technical Specifications

General Specifications

Certifications & Compliance

Typical Applications & Industries

Automotive Assembly and Body Shop

• Pre-specifying multi-station manifolds on automotive body assembly fixtures with blanking kits installed in reserved positions to accommodate future model year changeover requirements without manifold replacement.
• Maintaining manifold pressure integrity on welding robot control manifolds during machine reconfiguration periods when selected valve stations are removed for tooling changes and new valves are not yet available.
• Installing blanking kits in spare manifold positions on transfer line pneumatic control manifolds as part of standardized spare part and maintenance practice, enabling rapid valve addition during production ramp-up activities.

Packaging Machinery and Food Processing

• Specifying packaging machine manifolds with growth stations to accommodate future format expansion, fitting blanking kits in unfilled positions to maintain system pressure and cleanliness standards during initial production.
• Protecting unused manifold station openings in hygienic packaging environments from contamination, dust, and liquid ingress using fully sealed blank station plate and gasket kits.
• Enabling modular machine build practices where manifold assemblies are standardized across multiple machine variants, with blanking kits filling positions not required for a specific machine configuration.

Machine Tool and General Industrial

• Filling reserved stations in standard manifold assemblies for machine tool families that share a common manifold platform but use different numbers of pneumatic axes depending on machine configuration.
• Protecting manifold gasket surfaces from mechanical damage during machine installation, transportation, and storage by installing blanking kits on all open positions until valve installation is complete.
• Maintaining system pressure in partially filled manifolds during commissioning phases where all pneumatic circuits are not yet connected or activated.

Semiconductor and Electronics Manufacturing

• Clean-room compatible blank station covers for ISO 15407 W66 Series manifolds in semiconductor process equipment, preventing particle ingress into unused manifold port openings during equipment qualification and process development.
• Manifold growth positions for automated test equipment where additional valve stations may be required to support future device types or test configurations.

Pharmaceutical and Life Sciences

• Sterile-area compatible manifold blanking kits for ISO 5599 manifolds in pharmaceutical processing equipment, maintaining the cleanability and leak-free integrity of unused manifold positions during GMP-compliant validation activities.
• Reserved expansion capacity for modular automated filling and packaging line manifolds in pharmaceutical environments where production scale-up may require additional valve stations post-initial validation.

OEM Machine Building

• Standard manifold blanking kit inventory for OEM machine builders producing multiple machine configurations from a common manifold platform, enabling build-to-order configuration of valve stations while maintaining a single manifold SKU.
• Machine upgrade facilitation for installed base service, allowing field technicians to expand existing manifold assemblies by removing blanking kits and installing new valve stations without manifold hardware replacement.

Ordering and Model Number Configuration

Manifold Blanking Kits are ordered by selecting the kit number corresponding to the applicable valve series, ISO size, and manifold standard. Each kit is a complete assembly.

For ISO 5599-2 W65 Series: Size 1 = 1375N77 or 1381N77; Size 2 = 1377N77 or 1382N77; Size 3 = 1379N77 or 1380N77.

For ISO 5599-1 W60/W64 Series: Size 1 = 546H77; Size 2 = 694K77; Size 3 = 537H77.

For ISO 15407-1 W66 Series: Size 00 = RDX02BLK; Size 0 = RDX01BLK.

For ISO 15407-2 W66 Series: Size 00 = RPS5634P; Size 0 = RPS5534P.

For SAE Series: Size 125 = 820K77; Size 250 = 821K77; Size 500 = 822K77.

Each kit includes blank station plate, gasket, and mounting bolts. No additional hardware is required for installation.

Contact ROSS Controls at (800) 438-7677 for 95 Series blanking kit selection and to confirm compatibility with specific manifold model numbers.

Related Products & Accessories

• ISO 5599-2 W65 Series Valves - ISO 5599-2 base-mounted spool and sleeve valves for which 1375N77, 1377N77, and 1379N77 blanking kits are designed. https://www.rosscontrols.com/en/series/243-iso-5599-2-w65-series
• ISO 5599-1 W60 and W64 Series Valves - ISO 5599-1 base-mounted valves for which 546H77, 694K77, and 537H77 blanking kits apply. https://www.rosscontrols.com/en/series
• ISO 15407 W66 Series Valves - ISO 15407-1 and ISO 15407-2 W66 Series valves for which RDX02BLK, RDX01BLK, RPS5634P, and RPS5534P apply. https://www.rosscontrols.com/en/series
• Series 99 Interposed Modules - Flow controls, independent pressure plates, and exhaust modules for individual manifold stations. https://www.rosscontrols.com/en/series/99-interposed-modules
• Series 101 Blocking Disc - Blocking discs for isolating supply, exhaust, and pilot ports between manifold stations. https://www.rosscontrols.com/en/series/101-blocking-disc
• Series 102 Base Size Transition Plate - Transition plates for connecting different ISO valve sizes in the same manifold assembly. https://www.rosscontrols.com/en/series/102-base-size-transition-plate

Frequently Asked Questions (FAQ)

Q: Why do I need a manifold blanking kit instead of simply leaving a station open?

A: An open manifold station exposes the supply galley port openings and valve mounting surface to the atmosphere. Without a gasket and blank plate, compressed air will exhaust freely from the open supply ports, causing air loss, reduced system pressure, and increased compressor load. Debris and contaminants can also enter the manifold through open stations, leading to valve contamination and premature failure. A blanking kit maintains pressure integrity and cleanliness of the entire manifold assembly.

Q: Can I upgrade from a blanking kit position to an active valve station later?

A: Yes. This is the primary design intent of manifold blanking kits. When ready to add a valve station, remove the blank plate and gasket, install the valve sub-base or valve with gasket in the station position using the same mounting holes, and connect supply, exhaust, and electrical connections. No manifold replacement is required.

Q: What is included in each blanking kit?

A: Each Manifold Blanking Kit includes three components: the blank station plate (a solid metal plate matching the valve station footprint), the appropriate manifold surface sealing gasket, and the correct mounting bolts for the applicable valve platform. No additional hardware needs to be purchased separately.

Q: Are there different blanking kits for ISO 5599-1 and ISO 5599-2 manifolds of the same ISO size?

A: Yes. ISO 5599-1 (W60/W64 Series) and ISO 5599-2 (W65 Series) manifolds have different mounting interfaces and port patterns despite sharing the same ISO size designation. Blanking kits are not interchangeable between 5599-1 and 5599-2 platforms. Always confirm the standard (5599-1 or 5599-2) and valve series when selecting a blanking kit.

Q: What are the price points for Manifold Blanking Kits?

A: Based on listed variant pricing, manifold blanking kits range from approximately $3.50 (model 1806H77) to $56.50 (models 1381N77 and 1382N77). Lower-priced kits are typically smaller ISO sizes or simpler configurations. Contact ROSS Controls at (800) 438-7677 for complete current pricing across all available models.

Q: Can blanking kits be used in SAE manifold assemblies?

A: Yes. SAE manifold blanking kits are available for SAE Sizes 125 (820K77), 250 (821K77), and 500 (822K77). These kits are designed for the SAE 80/84 Series valve manifold mounting interface and should not be interchanged with ISO or ANSI platform kits.

Q: How do I verify a blanking kit installation is leak-free?

A: After tightening the mounting bolts to the specified torque in a cross pattern, gradually restore system pressure with the manifold energized and use soapy water or a leak detection spray on all interfaces around the blank plate perimeter. Bubbles indicate a leak, which typically means the gasket is misaligned or the blank plate torque is insufficient. Re-torque or re-seat the gasket and retest.

Q: Do blanking kits require a special gasket, or is any flat gasket acceptable?

A: Always use the gasket included in the ROSS blanking kit for the specific valve platform and size. Third-party flat gaskets may not match the manifold port pattern correctly, could be made of incompatible materials, or may have incorrect thickness, leading to leakage or platform incompatibility. Using non-ROSS gaskets could also void the valve manifold warranty.

Q: Is the blank station plate for ISO 5599-1 a specific material?

A: Per ROSS catalog data, the ISO 5599-1 blank station plate is a metal plate 0.32 inches (8 mm) thick. The specific metal alloy is not explicitly published; contact ROSS Controls for material certification requirements in corrosive environment applications.

Q: Can blanking kits be ordered as spare parts for installed manifolds?

A: Yes. Blanking kits are available as individual spare part orders from ROSS Controls and authorized distributors. It is good practice to keep one blanking kit per manifold size on hand to re-seal station positions after valve removal for maintenance or repair, maintaining manifold pressure integrity while replacement valves are obtained.

Installation & Maintenance Guidelines

• Before installation, lock out and tag out all energy sources and exhaust all downstream pneumatic pressure to zero per OSHA 1910.147.
• Clean the manifold station mounting surface thoroughly to remove any debris, machining oils, or sealing compound residue before installing the gasket.
• Position the gasket on the manifold station surface, ensuring all port openings are covered and the gasket is correctly aligned with the mounting holes.
• Place the blank station plate over the gasket and insert the mounting bolts. Tighten bolts in a cross pattern to the torque specification in the applicable valve series installation instruction.
• Do not over-tighten mounting bolts, as this can distort the gasket and cause leakage or damage to the manifold surface.
• After installation, gradually reintroduce system pressure and verify there are no leaks at the blanking kit station interfaces using soapy water or an equivalent leak detection method.
• When removing a blanking kit to install a valve, inspect the gasket seat for damage before installing the valve sub-base gasket.
• Store unused blanking kits in a dry location, free of contact with lubricants or solvents that could degrade gasket material.

Warranty & Global Support

ROSS Controls provides a one-year warranty on all products, covering defects in material and workmanship from date of purchase.

Global technical support is available through ROSS offices in the USA, Canada, Brazil, Germany, France, United Kingdom, India, China, and Japan.

Contact ROSS Controls USA Customer Service at 1-800-GET-ROSS or Technical Service at 1-888-TEK-ROSS.

For kit compatibility with specific manifold model numbers and current pricing, visit rosscontrols.com or contact ROSS Controls at (800) 438-7677.