Multi-Station Manifolds 95 Valves Series

Product Overview

The ROSS Controls provides preassembled slim-line multi-station manifold bases for the ROSS 95 Series directional control valves. Each manifold is a factory-assembled, single-body unit sized for 2, 4, 6, 8, or 10 valve stations, providing shared internal supply and exhaust galleries for all stations in the manifold. The slim-line profile keeps the assembled valve bank compact, which is a critical advantage in panel installations and machine enclosures where space is limited.

The Series covers 95 Series valve configurations for 3/2 (3-port, 2-position) spring return and detented valves, and for 5/2 and 5/3 (5-port, 2-position and 5-port, 3-position) valves across all available port sizes: 1/8", 1/4", 3/8", and 1/2". Port sizes on the manifold correspond to the inlet and work port size of the 95 Series valve installed on each station. Both NPT and BSPP (G-thread) manifold bodies are available, with BSPP versions designated by the D prefix.

ROSS 95 Series valves feature resilient seal spool construction and are available in both inline and manifold-mounted configurations. When manifold-mounted, the valve body bolts directly to the manifold station using two mounting screws, with O-ring face seals forming the supply and exhaust interfaces between the valve and manifold base. Each station position is independent, allowing individual valves to be removed and replaced without disturbing adjacent stations.

As a design engineer specifying 95 Series manifold systems, the series simplifies system integration by providing a complete manifold body in one part number. Pre-drilled mounting holes, integral supply and exhaust passages, and included blanking kit accessories eliminate the need to specify and assemble individual manifold station components. The compact assembled dimensions of the series manifolds simplify panel layout for systems requiring 2 to 10 valve stations in a single pneumatic zone.

Key Engineering Features

• Slim-Line Single-Body Manifold Construction - Each Series manifold is a single machined aluminum body that provides all station positions, supply galleries, and exhaust galleries in one unit. This eliminates assembly stack-up tolerances associated with bolted-together per-station manifolds and delivers a consistently flat valve mounting interface across all stations.
• 2 to 10 Station Configurations - Manifolds are available in 2, 4, 6, 8, and 10 station increments for both 3/2 and 5/2 or 5/3 valve functions, providing direct selection of the exact station count required without over-specifying or under-specifying manifold capacity.
• Four Port Size Options (1/8", 1/4", 3/8", 1/2") - Port sizes cover the full range of 95 Series valve configurations. The 1/8" port size gives a maximum Cv of 0.9 (980 Nl/min), 1/4" gives 1.3 (1300 Nl/min), 3/8" and 1/2" sizes deliver up to 2.6 and 4.5 Cv respectively, providing appropriate flow capacity for each actuator size and cycle time requirement.
• 3/2 and 5/2 or 5/3 Valve Compatibility - Separate manifold series are available for 3/2 valve functions (1472H91 through 1500H91) and for 5/2 or 5/3 valve functions (1392H91 through 1650H91). The 5/2 or 5/3 manifold bodies are wider to accommodate the additional work ports of 5-port valves, and the model families are distinct to prevent mismatched installations.
• NPT and BSPP Thread Options - All Series manifolds are available in both NPT and BSPP (G-thread) configurations. BSPP versions are identified by the D prefix in the model number (e.g., D1392H91), supporting global installation requirements.
• Individual Station Valve Replacement - Each manifold station has independent valve mounting screws. Individual valve bodies can be removed and replaced from any station without disassembling the manifold body or disturbing valves at other stations, minimizing downtime during maintenance.
• Non-Locking Manual Override on All Valves - All 95 Series valves mounted on Series manifolds include non-locking pushbutton manual overrides accessible from the front of the valve body, enabling individual station actuation during setup and commissioning without energizing the solenoid circuit.
• Manifold Blanking Kits for Unused Stations - Blanking kits (1806H77 through 1809H77 for 5/2 or 5/3; 1813H77 or 1814H77 for 3/2) are available to seal unused valve positions in the manifold, allowing stations to be blocked off while maintaining system pressure in the supply gallery. Future station activation requires only blanking kit removal and valve installation.
• Solenoid and Connector Included with Valve - ROSS 95 Series valves mount to the series manifold with solenoid and electrical connector included, reducing component sourcing. Electrical connections use EN 175301-803 MICRO-MINI (1/8" port size) or Industrial Form B connectors (1/4" through 1/2" port sizes) compatible with ROSS lighted connector options.
• 60 Variants in the series - The Series includes 60 individual manifold models covering all station counts (2, 4, 6, 8, 10), all port sizes (1/8", 1/4", 3/8", 1/2"), both valve function types (3/2 and 5/2 or 5/3), and both thread standards (NPT and BSPP), providing comprehensive coverage of 95 Series manifold applications.

Technical Specifications

General Specifications

Flow Performance Data

Cv values below are for 95 Series valves mounted on manifold bases. Flow performance is specific to the valve, not the manifold base itself. Manifold supply and exhaust gallery Cv is designed to exceed the combined station flow capacity at rated pressure.

Certifications & Compliance

Typical Applications & Industries

Packaging and Labeling Machinery

• Form-fill-seal machines using 6 or 8-station Series manifolds with 1/4" port 5/2 valves to control forming box cylinders, sealing bar actuators, and product ejection pneumatics from a compact manifold bank integrated into the machine frame.
• Case erecting and carton sealing systems using 4-station Series manifolds with 3/8" 5/2 valves for higher-flow flap folding and press cylinders where a single supply connection serves multiple actuators.
• Labeling and coding machines using 2-station Series manifolds with 1/8" 3/2 valves for pilot signal control and low-flow actuators in space-constrained labeler cabinets.

Material Handling and Conveying

• Pneumatic diverter gates on sortation conveyors using 4 or 6-station Series manifolds with 1/4" 5/2 valves to control gate cylinders along a conveyor zone from one valve bank assembly.
• Pick-and-place transfer systems using 8 or 10-station Series manifolds with 1/8" 3/2 or 5/2 valves to control suction cup vacuum and blow-off at multiple gripper stations from a common supply manifold.
• Palletizer layer-forming pneumatics using 6-station Series manifolds with 3/8" 5/2 or 5/3 valves where multiple cylinder axes must be independently controlled with mid-position hold capability using closed center 5/3 valves.

Automotive and General Assembly

• Fixture clamping and locating systems in automotive assembly tooling using 4 or 6-station 1/4" or 3/8" Series manifolds to control clamp cylinders from a manifold mounted on the fixture body.
• Robotic end-of-arm tooling pneumatics using 2-station Series manifolds with 1/8" or 1/4" 5/2 valves to control gripper and vacuum circuits within the robot arm envelope.
• Multi-axis pneumatic press and forming tooling using 10-station Series manifolds with 1/2" 5/2 valves for high-flow cylinder control in high-cycle applications where each station cycles independently.

Food and Beverage Processing

• Filling, capping, and sealing machines using 4 to 8-station Series manifolds with 1/4" 5/2 valves to control individual filler actuators from a single manifold block that simplifies cleaning access in the filling zone.
• Conveying and product handling systems in food processing lines using Series manifolds with aluminum bodies that resist corrosion and tolerate the high-humidity environments common in food plant installations.
• Pneumatic portion control and gate systems using compact 2-station Series manifolds where individual actuator control and easy manual override access simplify routine production adjustments.

Ordering and Model Number Configuration

Select the series manifold by valve function type (3/2 or 5/2 or 5/3), port size (1/8", 1/4", 3/8", 1/2"), station count (2, 4, 6, 8, 10), and thread standard (NPT or BSPP via D prefix). For BSPP, add D prefix to the model number.

Manifolds for 3/2 valves and manifolds for 5/2 or 5/3 valves are separate product families with different body widths. Do not order a 3/2 manifold for use with 5/2 or 5/3 valves, as the port interface geometry differs.

For BSPP (G-thread) versions, add a D prefix to the NPT model number. All Series manifold models have corresponding BSPP variants.

Contact ROSS for custom station counts outside 2, 4, 6, 8, and 10 stations, or for complete valves-on-manifold assemblies preloaded with valve bodies before shipment.

Manifold blanking kits are ordered separately: 1806H77 (1/8"), 1807H77 (1/4"), 1808H77 (3/8"), 1809H77 (1/2") for 5/2 or 5/3 manifolds; 1813H77 (1/8") and 1814H77 (1/4") for 3/2 manifolds. Each blanking kit includes blanking plate, manifold gasket, and mounting bolts for one station.

Electrical connectors for 95 Series valves on manifolds are ordered separately: 1766L77 (24V DC, MICRO-MINI) or 1780L77 (110V AC, MICRO-MINI) for 1/8" port valves; 1767L77 (24V DC, Form B) or 1781L77 (110V AC, Form B) for 1/4" through 1/2" port valves.

Slim-Line Manifold Base for 3/2 Valves - 1/8" Port (NPT Model Numbers)

Slim-Line Manifold Base for 3/2 Valves - 1/4" Port (NPT Model Numbers)

Slim-Line Manifold Base for 5/2 and 5/3 Valves - 1/8" Port

Slim-Line Manifold Base for 5/2 and 5/3 Valves - 1/4" Port

Slim-Line Manifold Base for 5/2 and 5/3 Valves - 3/8" Port

Slim-Line Manifold Base for 5/2 and 5/3 Valves - 1/2" Port

Accessories

Manifold Blanking Kits for 3/2 Valve Manifolds

For blocking unused valve positions on 3/2 valve manifolds. Each kit contains a blanking plate, manifold gasket, and mounting bolts for one station position.

Manifold Blanking Kits for 5/2 and 5/3 Valve Manifolds

For blocking unused valve positions on 5/2 and 5/3 valve manifolds. Each kit contains a blanking plate, manifold gasket, and mounting bolts for one station position.

Electrical Connectors for 95 Series Valves

Three-pin electrical connectors with LED indicator and surge suppressor for 95 Series valves on Series manifolds. Select by valve port size and supply voltage.

Exhaust Silencers for 95 Series Manifold Exhaust Ports

Aluminum exhaust silencers rated to 290 psig (20 bar) for manifold exhaust ports. Available in male thread configurations matched to manifold exhaust port sizes.

Warning: Exhaust silencers must have Cv ratings equal to or greater than the combined exhaust Cv of all simultaneously venting valve stations on the manifold. An undersized silencer creates backpressure on the exhaust gallery, reducing actuator return speed across all manifold stations.

Related Products & Accessories

• 95 Series Directional Control Valves - Resilient seal spool 3/2, 5/2, and 5/3 directional control valves in 1/8" through 1/2" port sizes for inline or manifold mounting on Series manifold bases. https://www.rosscontrols.com/en/documents/8/95-series-valves
• 249 Series Single Sub-bases - Individual sub-bases for ISO, ANSI, SAE, and W14 valves where single-valve installations are required. https://www.rosscontrols.com/en/series/249-single-sub-bases
• 250 Series Manifold Sub-bases - Per-station manifold sub-bases for ISO, ANSI, SAE, and W14 valve standards that assemble into multi-station manifold banks using 251 Series end station kits. https://www.rosscontrols.com/en/series/250-manifold-sub-bases
• 251 Series End Station Kits - End plates and hardware for terminating ISO 5599/I, ISO 5599/II, and ISO 15407 manifold banks assembled with 250 Series sub-bases. https://www.rosscontrols.com/en/series/251-end-station-kits
• Valve Manifold Base Options - Interposed regulators, blanking plates, and blocking discs for ISO 15407, ISO 5599, and 95 Series valve manifold bases. https://www.rosscontrols.com/en/categories/1305-valve-manifold-base-options
• Exhaust Silencers - Aluminum silencers rated to 290 psig for manifold exhaust ports in port sizes 1/8" through 1/2". https://www.rosscontrols.com/en/series/90-silencers
• Electrical Connectors - EN 175301-803 Form B and MICRO-MINI connectors for 95 Series valves with LED indication and surge suppression. https://www.rosscontrols.com/en/series/91-electrical-connectors

Frequently Asked Questions (FAQ)

Q: What is the difference between a Series multi-station manifold and a 250 Series manifold sub-base?

A: A Series multi-station manifold is a single-body preassembled unit for ROSS 95 Series valves, available in 2 to 10 station sizes in one part number. A 250 Series manifold sub-base is a per-station component for ISO, ANSI, SAE, and W14 valve standards that must be bolted together with other stations and terminated with a 251 Series end station kit. The Series is used exclusively with 95 Series valves; the 250 Series covers all other ROSS base-mounted valve families.

Q: Can I use a 5/2 valve on a 3/2 manifold from the series?

A: No. The 3/2 manifold (1472H91 through 1500H91 series) and the 5/2 or 5/3 manifold (1392H91 through 1650H91 series) have different valve interface geometries. The 5/2 or 5/3 manifold is wider and has different internal port arrangements than the 3/2 manifold. Installing a 5/2 valve on a 3/2 manifold will result in misaligned internal passages and potential supply or exhaust cross-connection.

Q: What is the operating pressure range for Series manifolds?

A: The Series manifold is rated for 22.5 to 150 psig (1.5 to 10 bar) inlet pressure, matching the operating range of the 95 Series valves they support. Operating below 22.5 psig may result in incomplete valve shifting. Operating above 150 psig exceeds the rated design pressure of the valve and manifold body.

Q: How do I select the correct station count for my application?

A: Count the number of independent actuator circuits to be controlled from the manifold bank. Select the next available station count equal to or greater than the required valve count. For example, if 5 valves are required, select a 6-station manifold. The extra station can be blocked with a blanking kit and activated later if an additional actuator is added. Ordering a larger manifold than immediately needed avoids retrofitting the manifold body when the system is expanded.

Q: What is the temperature rating for Series manifolds?

A: The operating temperature range is 41 to 140F (5 to 60C) for both ambient and media conditions. This is determined by the 95 Series valve seals and solenoid materials, not the aluminum manifold body itself. Operating outside this range will accelerate seal wear and may affect solenoid performance. For applications near or exceeding 140F, contact ROSS to discuss alternative valve and seal configurations.

Q: Do the manifolds ship with valves already installed?

A: No. Standard Series manifolds are manifold bodies only, without valve bodies. Valves are ordered separately using 95 Series valve model numbers and are installed on the manifold after delivery. ROSS can supply complete valves-on-manifold assemblies with specified valve configurations preinstalled at the factory. Contact ROSS for factory-assembled valve-on-manifold ordering.

Q: How do I specify BSPP threads for a Series manifold?

A: Add a D prefix to the NPT model number. For example, the 1414H91 is the 1/4" port, 4-station, 5/2 or 5/3 NPT manifold; D1414H91 is the identical manifold with BSPP (G-thread) port connections. All Series manifold models have corresponding BSPP variants.

Q: Can I use a Series manifold with air pilot controlled 95 Series valves?

A: Yes. 95 Series air pilot controlled valves mount on Series manifolds using the same interface. Air pilot controlled valves are specified when electrical solenoids cannot be used, such as in explosive atmospheres or electrically sensitive environments. The manifold body is identical; only the valve function and actuation type changes.

Q: What electrical connectors are available for 95 Series valves on manifolds?

A: For 1/8" port valves, use EN 175301-803 MICRO-MINI connectors: 1766L77 (24V DC with LED and surge suppressor) or 1780L77 (110V AC with LED and surge suppressor). For 1/4", 3/8", and 1/2" port valves, use Industrial Form B connectors: 1767L77 (24V DC) or 1781L77 (110V AC). All connectors include LED indicator and surge suppression.

Q: How do I block an unused station on a Series manifold?

A: Install a manifold blanking kit on the unused station. For 5/2 or 5/3 manifolds, use 1806H77 (1/8"), 1807H77 (1/4"), 1808H77 (3/8"), or 1809H77 (1/2"). For 3/2 manifolds, use 1813H77 (1/8") or 1814H77 (1/4"). Each blanking kit includes a blanking plate, manifold gasket, and mounting bolts. The blanking plate seals the valve port interface, allowing the manifold supply gallery to remain pressurized without leakage at the unused station.

Q: What is the power consumption of 95 Series valves on the manifold?

A: DC solenoid valves consume 2.5 watts continuously at 24V DC. AC solenoid valves draw 3.6 VA holding current at 110/120 VAC, 50/60 Hz. All solenoids are rated for continuous duty at rated voltage without derating. Plan PLC output modules and solenoid power supplies to support the sum of all simultaneously energized valve solenoids in the manifold bank.

Q: Can the series manifolds be mounted in any orientation?

A: Yes. 95 Series valve and manifold assemblies can be mounted in any orientation. Vertical mounting with the valve bodies facing horizontally is common in panel installations. Inverted mounting with the valve faces pointing down is acceptable. Condensate drainage considerations apply in humid environments; ensure that any condensate in the supply line is drained upstream of the manifold and does not accumulate in the manifold supply gallery.

Installation & Maintenance Guidelines

• Before mounting the manifold, verify that the model number matches the valve function type (3/2 or 5/2 or 5/3), port size, station count, and thread standard required by the application. Installing a mismatched manifold type will prevent proper valve installation.
• Mount the manifold body to the machine structure, panel, or DIN rail before installing valve bodies. Secure all manifold mounting screws to specified torque before proceeding. Applying loads to the manifold through the valve bodies during mounting can cause alignment errors.
• Inspect all valve-to-manifold interface O-rings before installing each valve. These seals are included with the valve body. Replace any seal showing nicking, extrusion marks, or deformation. Proper O-ring seating is critical for supply and exhaust gallery integrity.
• Install valve bodies on the manifold by aligning the valve body ports with the manifold station openings, placing the O-rings in their grooves, and tightening the two mounting screws evenly. Do not tighten one screw fully before starting the other; alternating torque prevents cocking the valve body on the interface seals.
• Connect supply air to the manifold supply port sized for the total simultaneous flow demand of all valve stations. For 1/8" port manifolds, a 1/4" supply connection is used. For 1/4" port manifolds, a 1/4" or 3/8" supply connection is appropriate depending on station count. For 3/8" and 1/2" port manifolds, size the supply connection for the combined maximum Cv of all stations.
• Route individual work port tubing from each station to the corresponding actuator. Label all work port connections before pressurizing the system. On multi-station manifolds, work port connections for adjacent stations are close together; mispiping a work port to an adjacent station causes incorrect actuator motion.
• Install exhaust silencers on all manifold exhaust ports before startup. The exhaust silencer Cv must equal or exceed the combined exhaust Cv of all stations that may vent simultaneously. Undersized silencers increase exhaust backpressure across the manifold gallery and reduce actuator return speed.
• Before connecting solenoid wiring, verify that the supply voltage matches the valve solenoid voltage specification (24V DC or 110/120V AC). Applying incorrect voltage to a solenoid will cause coil failure. Use DIN connectors matched to the valve port size (MICRO-MINI for 1/8" port, Form B for 1/4" through 1/2" port).
• After all valve bodies, piping, and electrical connections are complete, apply supply pressure gradually while monitoring for leakage at the valve-to-manifold interfaces, supply port fitting, and exhaust port fitting. Confirm no leakage before proceeding to functional testing.
• Test each valve station individually using the non-locking manual override button on the valve body. Confirm that each actuator extends and retracts correctly before energizing any solenoids. This step identifies mis-piped work ports before machine operation.
• For unused manifold stations, install blanking kits before startup. An uncapped unused station will exhaust supply air continuously through the open valve port interface, depleting system pressure and causing erratic operation at active stations.
• Document all manifold model numbers, valve model numbers, and work port wiring connections in the machine records at installation. This information is required for spare parts ordering, valve replacement, and troubleshooting after the machine is in service.

Warranty & Global Support

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

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

For manifold selection, 95 Series valve configuration, and factory-assembled valve-on-manifold ordering, contact ROSS Controls at +1-248-764-1800 or visit rosscontrols.com.

For complete technical data, dimensional drawings, and CAD models for Series manifolds, visit the ROSS Controls product page or contact ROSS Controls at (800) 438-7677.

Download Catalog: https://www.rosscontrols.com/en/documents/8/95-series-valves