Base Size Transition Plate For ISO Series Valves

Product Overview

The ROSS Controls Base Size Transition Plates are machined adapter modules that install between adjacent stations of different ISO sizes within the same pneumatic valve manifold assembly, connecting the supply (Port 1) and exhaust (Ports 3 and 5) galleys across the size transition interface. Without a transition plate, ISO valve manifolds can only accommodate one ISO size throughout the assembly; transition plates eliminate this constraint, enabling engineers to mix ISO sizes in a single manifold to match actuator flow requirements without designing separate manifold sections.

For ISO 5599-2 W65 Series manifolds, transition plates are available in four bidirectional configurations: Size 1 to Size 2 (1387N77), Size 2 to Size 1 (1388N77), Size 2 to Size 3 (1389N77), and Size 3 to Size 2 (1390N77). For ISO 5599-1 W60/W64 Series manifolds, transition plates D355K86 (Size 1 to 2), D356K86 (Size 2 to 3), and D357K86 (Size 1 to 3) handle all three common size transitions, including a direct jump from Size 1 to Size 3.

Transition plates are installed between the two manifold stations of different sizes during assembly, bridging the port size mismatch while maintaining continuous supply and exhaust galley connectivity. This capability is particularly valuable in machine designs where most actuators are standard force/flow requirements served by Size 1 or Size 2 valves, but one or two high-flow or high-force actuators require a Size 2 or Size 3 valve within the same machine frame.

For OEM machine builders and system engineers designing compact, integrated pneumatic assemblies, Transition Plates reduce manifold hardware count, simplify installation, and provide the design flexibility to right-size each valve station for its specific actuator without forcing a uniform ISO size selection across the entire system.

Key Engineering Features

• Mixed ISO Size Manifold Capability - Enables ISO valve manifolds to combine valves of different ISO sizes (e.g., Size 1 and Size 2, or Size 2 and Size 3) in a single assembly, matching flow and force requirements at each station without imposing a system-wide ISO size constraint.
• Supply and Exhaust Galley Bridge - The transition plate connects the Port 1 (supply), Port 3 (exhaust A), and Port 5 (exhaust B) galley passages between adjacent manifold stations of different sizes, maintaining continuous pneumatic connectivity across the size transition interface.
• ISO 5599-2 W65 Series Coverage - Four transition plate configurations (1387N77, 1388N77, 1389N77, 1390N77) cover all bidirectional ISO size transitions (1 to 2, 2 to 1, 2 to 3, 3 to 2) for ISO 5599-2 W65 Series manifolds.
• ISO 5599-1 W60/W64 Series Coverage - Three transition plate models (D355K86, D356K86, D357K86) cover size transitions 1 to 2, 2 to 3, and 1 to 3 (direct jump) for ISO 5599-1 W60/W64 Series manifolds.
• Compact Interface Module - Transition plates are installed between valve stations without requiring additional external plumbing, brackets, or piping, maintaining the compact, integrated appearance of the manifold assembly.
• Design Flexibility Without Manifold Compromise - Eliminates the need to either oversize all valve stations to match the largest actuator requirement or to design physically separate manifold assemblies for each valve size group.

Technical Specifications

General Specifications

Certifications & Compliance

Typical Applications & Industries

Automotive Assembly and Body Shop

• Combining ISO Size 1 valve stations for small-bore sensor actuation cylinders and ISO Size 2 or Size 3 valve stations for large-bore clamp cylinders in the same body shop fixture manifold, reducing the manifold assembly to a single unit instead of separate same-size assemblies.
• Integrating high-flow Size 3 valve stations for part transfer gripper cylinders with Size 1 stations for part detection logic actuators in a single automotive assembly transfer system manifold, using transition plates at the size interface.
• Manifold consolidation on automotive press transfer lines where Size 2 valves serve die-set actuators and Size 3 valves serve main ram counterbalance circuits, enabling a single manifold assembly to cover the full circuit.

Packaging and Converting Machinery

• Combining Size 1 valve stations for lightweight bag folding actuators with Size 2 stations for heavier carton erecting mechanisms in a single packaging machine manifold, matching cylinder bore and flow requirements at each station.
• Integrating Size 2 and Size 3 valve stations within a single palletizing machine manifold, where arm sweep cylinders require Size 3 flow capacity and product layer diverters are adequately served by Size 2 valves.
• Multi-format packaging line manifolds where different product formats require different cylinder sizes and flow rates, accommodated in a single expandable manifold assembly using transition plates at size change points.

Machine Tool and Industrial Automation

• CNC machining center pneumatic manifolds combining Size 1 tool change confirmation sensors with Size 2 door lock cylinders and Size 3 part clamp cylinders in a single compact manifold assembly mounted on the machine column.
• Gantry system manifolds where Z-axis brake cylinders require high-flow Size 3 valves and XY-axis position confirmation sensors use Size 1 valves, all integrated in one manifold assembly using transition plates.

Press Control and Metal Forming

• Press clutch/brake manifold assemblies where pilot stage valves can be Size 1 and main stage valves require Size 3, combined in a single manifold assembly using Size 1 to Size 3 direct transition plates (D357K86).
• Tandem press line shared manifold assemblies where individual press control circuits operate at different flow requirements, accommodated by size transitions within a single manifold instead of parallel same-size manifold arrays.

Semiconductor and Electronics Manufacturing

• Wafer handling equipment manifolds combining Size 00 (ISO 15407) micro-flow control for precision vacuum chuck valves with larger-flow stations for coarse-position actuators in a single integrated manifold assembly.
• Test handler manifolds integrating fine-pitch part placement cylinder valves with higher-flow fixture clamping cylinder valves in a single assembly, reducing overall manifold footprint in space-constrained test equipment enclosures.

General Industrial and OEM Machine Building

• Standardized manifold design for OEM machine families where the base manifold accommodates all ISO sizes using transition plates, allowing individual customer configurations to add larger valve stations without redesigning the manifold platform.
• Retrofit manifold upgrades for existing installations where a new high-flow actuator must be added to an installed manifold assembly of a different ISO size, using a transition plate to bridge the size difference at the new station location.

Ordering and Model Number Configuration

Base Size Transition Plates are ordered by selecting the model number corresponding to the manifold standard and the specific ISO size transition required. Specify left-to-right orientation (left station size to right station size) when ordering.

For ISO 5599-2 W65 Series: Size 1 to 2 = 1387N77 ($512.75); Size 2 to 1 = 1388N77 ($230.25); Size 2 to 3 = 1389N77 ($279.50); Size 3 to 2 = 1390N77 (contact ROSS).

For ISO 5599-1 W60/W64 Series: Size 1 to 2 = D355K86; Size 2 to 3 = D356K86; Size 1 to 3 direct = D357K86.

Transition direction matters: the model number specifies which size is on the left (inlet) side and which is on the right (outlet) side of the transition plate. Verify orientation against the manifold layout drawing before ordering.

Transition plates are installed between manifold stations. The manifold assembly must include end station kits for each end of the manifold, appropriate to the ISO size at each end.

Contact ROSS Controls at (800) 438-7677 for transition plate availability for ANSI, SAE, and non-standard manifold platforms, as well as for Size 3 to 2 (1390N77) current pricing.

Related Products & Accessories

• ISO 5599-2 W65 Series Valves - ISO 5599-2 base-mounted spool and sleeve valves in Sizes 1, 2, and 3 for which 1387N77 through 1390N77 transition plates 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 D355K86, D356K86, and D357K86 transition plates apply. https://www.rosscontrols.com/en/series
• Series 100 Manifold Blanking Kit - Blank station kits for unused manifold positions. https://www.rosscontrols.com/en/series/100-manifold-blanking-kit
• Series 101 Blocking Disc - Port isolation discs for creating pressure zones within ISO valve manifolds. https://www.rosscontrols.com/en/series/101-blocking-disc
• Series 98 Interposed Regulators - Per-station pressure regulation modules for ISO manifolds. https://www.rosscontrols.com/en/series/98-interposed-regulators
• Series 99 Interposed Modules - Flow controls, pressure plates, and shut-offs for individual ISO manifold stations. https://www.rosscontrols.com/en/series/99-interposed-modules

Frequently Asked Questions (FAQ)

Q: What does a base size transition plate actually do?

A: A base size transition plate is a machined adapter installed between two adjacent manifold stations of different ISO sizes. It physically bridges the mismatch in port dimensions and galley sizes at the interface, connecting the supply and exhaust galley passages from the smaller station to the larger station, allowing air to flow continuously through the manifold assembly across the size change point.

Q: Why would I want to mix ISO sizes in one manifold?

A: Different pneumatic actuators have different flow and force requirements. Small-bore, short-stroke sensors and confirmation cylinders are adequately served by Size 1 valves (Cv approximately 0.8). Large-bore, high-force clamp or transfer cylinders may require Size 2 (Cv approximately 1.9) or Size 3 (Cv approximately 3.8) valves. Using transition plates lets you right-size each valve station for its specific actuator, avoiding the waste of over-sizing all stations to match the largest actuator, or the complexity of designing multiple separate manifold assemblies.

Q: Does the transition plate affect the supply pressure reaching each manifold section?

A: No. The transition plate simply provides a physical passage for supply and exhaust air to pass between stations of different sizes. It does not regulate, restrict, or alter the supply pressure. Both manifold sections on either side of the transition plate receive the same supply pressure from the common manifold supply galley, unless a blocking disc or interposed pressure plate is also installed at the same interface to create a pressure zone boundary.

Q: Is the transition direction (e.g., Size 1 to Size 2 vs. Size 2 to Size 1) important?

A: Yes. For ISO 5599-2 W65 Series, separate part numbers exist for each direction: 1387N77 is Size 1 to Size 2 (left to right) while 1388N77 is Size 2 to Size 1. The transition plate is asymmetric because the port sizes differ on each face. Always verify the directional orientation against your manifold layout drawing before ordering.

Q: Is there a transition plate that goes directly from ISO Size 1 to ISO Size 3?

A: Yes, but only for ISO 5599-1 W60/W64 Series manifolds. Model D357K86 provides a direct Size 1 to Size 3 transition without an intermediate Size 2 station. For ISO 5599-2 W65 Series, a direct Size 1 to Size 3 transition is not available as a single part; two transition plates (1 to 2 and 2 to 3) would be needed to achieve the same result with an intermediate station in between.

Q: What are the dimensions of the ISO 5599-1 transition plates?

A: For ISO 5599-1 W60/W64 Series: the Size 1 to 2 transition plate (D355K86) measures 5.31 x 0.78 x 1.77 inches (135 x 20 x 45 mm). The Size 2 to 3 and Size 1 to 3 transition plates (D356K86, D357K86) measure 7.48 x 1.26 x 2.16 inches (190 x 32 x 55 mm).

Q: Can I use a blocking disc at the same location as a transition plate?

A: A blocking disc and a transition plate are generally not installed at the exact same station interface simultaneously, as they serve opposing functions: the transition plate connects supply and exhaust galleys across the interface, while a blocking disc isolates them. If independent supply zones are required across a size transition, a separate blocking arrangement on one side of the transition plate is typically designed at an adjacent station interface rather than at the transition plate itself. Contact ROSS for guidance on specific multi-function manifold layouts.

Q: Are transition plates available for ISO 15407 W66 Series manifolds?

A: ISO 15407 W66 Series manifolds are available in only two sizes (Size 00 at 18mm and Size 0 at 26mm). Transition plate availability for mixing Size 00 and Size 0 within a single ISO 15407 manifold should be confirmed directly with ROSS Controls. The 1387N77 through 1390N77 models are specific to ISO 5599-2 W65 Series, and D355K86/D356K86/D357K86 are specific to ISO 5599-1 W60/W64 Series.

Q: What is the price range for Transition Plates?

A: Listed prices for ISO 5599-2 W65 Series transition plates range from $230.25 (model 1388N77, Size 2 to 1) to $512.75 (model 1387N77, Size 1 to 2). ISO 5599-1 transition plate pricing is not published on the website; contact ROSS Controls at (800) 438-7677 for current pricing on all models.

Q: Can transition plates be used in the middle of a long manifold assembly, or only at the ends?

A: Transition plates can be installed at any station interface within a manifold assembly, not just at the ends. For example, a manifold could begin with several Size 1 stations, transition to Size 2 using a transition plate, continue with Size 2 stations, and then transition to Size 3 using another transition plate, all within a single continuous manifold assembly. Each transition plate location corresponds to the physical interface between stations of different sizes.

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.
• Plan the manifold assembly layout drawing to confirm the ISO size of each station and the location of each required transition plate before beginning assembly.
• Transition plates are installed between adjacent manifold stations of different sizes during manifold assembly. Ensure the transition plate is oriented correctly (left station size to right station size as specified by the part number).
• Verify that all required gaskets are present and correctly positioned on both interfaces of the transition plate before bolting.
• Torque mounting hardware at the transition plate interfaces to the specifications in the applicable valve series manifold assembly instruction.
• After manifold assembly, gradually restore system pressure and verify continuous supply and exhaust connectivity across the transition plate interface using pressure gauge measurements at each size section.
• Check for leakage at all transition plate sealing interfaces using soapy water or equivalent leak detection method.
• Document the transition plate locations in the manifold assembly drawing and maintenance records for future reference during manifold modification or servicing.

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 transition plate compatibility, directional orientation guidance, and manifold layout assistance, visit rosscontrols.com or contact ROSS Controls at (800) 438-7677.