Blocking Disc For ISO 15407 and ISO 5599 Series Valves

Product Overview

The ROSS Controls Blocking Discs are flat sealing discs that close the supply (Port 1), exhaust (Ports 3 and 5), and pilot port galleys between adjacent stations in ISO 15407 and ISO 5599 base-mounted valve manifold assemblies. By inserting a blocking disc in the appropriate galley hole at the interface between two manifold stations, the engineer creates an isolated pressure or exhaust zone within the manifold, allowing different stations on either side of the disc to operate at different pressures or to use separate exhaust paths.

Blocking discs are available as single discs for specific port isolation and as multi-disc kits containing three discs for complete main galley isolation (supply plus both exhausts) at a single interface. For ISO 5599-1 W60/W64 Series, individual disc models 235A40, 236A40, and 237A40 correspond to Sizes 1, 2, and 3 respectively, while kits 1007K77, 1008K77, and 1009K77 provide three discs for complete station interface isolation. For ISO 5599-2 W65 Series, kits 1376N77, 1378N77, and 1380N77 are available for Sizes 1, 2, and 3.

For ISO 15407 W66 Series manifolds, manifold port isolation kits RD02BD0 (Size 00) and RD01BD0 (Size 0) use O-ring-equipped plugs to close main galley ports (Ports 1, 3, and 5). ISO 5599-2 W65 Series manifold port isolation kits RPS4033CP (main galley) and pilot galley kits RPS4032CP/4132CP/4232CP provide plug-with-O-ring type isolation for those platforms. A separate pilot port blocking plug is also available for ISO 5599-2 W65 Series to block pilot ports between stations.

For machine builders, process engineers, and system designers specifying multi-zone pneumatic manifold systems, Blocking Discs provide the simplest, lowest-cost method for creating pressure zones, independent exhaust paths, or pilot isolation within a single manifold body without designing separate manifold sections or adding external isolation valves.

Key Engineering Features

• Supply and Exhaust Port Isolation - Blocking discs seal the Port 1 (supply), Port 3 (exhaust A), and Port 5 (exhaust B) galley openings at the interface between two manifold stations, allowing stations on each side to operate from independent supply or exhaust connections.
• Pilot Port Isolation - Pilot galley blocking is available for ISO 5599-2 W65 Series manifolds (kits RPS4032CP, RPS4132CP, RPS4232CP), enabling independent pilot supply for individual valve stations or sections of the manifold.
• Single Disc and Multi-Disc Kit Options - Single discs allow selective port isolation (supply only, or exhaust only). Three-disc kits provide simultaneous isolation of all main galley ports (supply, exhaust A, and exhaust B) at a station interface, enabling complete manifold section separation.
• ISO 5599-1 and ISO 5599-2 Coverage - Distinct blocking disc families for ISO 5599-1 W60/W64 Series (235A40/236A40/237A40 single; 1007K77/1008K77/1009K77 kits) and ISO 5599-2 W65 Series (1376N77/1378N77/1380N77 kits), covering all three ISO sizes on both standards.
• ISO 15407 Port Isolation Kits - Plug-with-O-ring isolation kits (RD02BD0 for Size 00; RD01BD0 for Size 0) for ISO 15407 W66 Series manifolds, as well as ISO 5599-2 W65 Series isolation kits RPS4033CP for main galley and pilot galley kits by size.
• Compact, Low-Cost Installation - Blocking discs are inserted at the manifold station interface during manifold assembly, requiring no additional hardware or machining. Cost per isolation point is very low compared to splitting a manifold into physically separate sections.

Technical Specifications

General Specifications

Certifications & Compliance

Typical Applications & Industries

Automotive Assembly and Robotic Manufacturing

• Creating independent supply pressure zones within a single automotive assembly manifold, using blocking discs to separate the high-pressure supply section for heavy clamp cylinders from the low-pressure section serving part detection sensors and lightweight guides on the same manifold body.
• Isolating independent exhaust paths for different manifold sections on automotive body shop fixtures, preventing back-pressure interference between high-flow clamp actuators and low-flow part sensor circuits exhausting through the same manifold.
• Pilot galley isolation between manifold sections on pilot-controlled valve manifolds, allowing different sections of the manifold to receive pilot supply from different pneumatic control circuits.

Packaging and Converting Machinery

• Separate supply zones within a single carton erecting manifold using blocking discs, enabling low-pressure actuation for gentle product contact stations and higher pressure for structural carton forming stations in the same manifold body.
• Independent exhaust routing for manifold stations serving vacuum generator and positive pressure circuits on bag-form-fill-seal machines, preventing vacuum loss through shared exhaust galleys.
• Main galley blocking between manifold sections on multi-format packaging lines to enable one section to be depressurized for format changeover tooling while the adjacent section remains in production.

Stamping, Press Control, and Metal Forming

• Pressure zone isolation within press clutch/brake manifolds to allow upper and lower press deck circuits to operate at different supply pressures from the same manifold, using blocking discs to separate the supply galley at the inter-zone interface.
• Independent pilot supply isolation on valve manifolds for tandem press lines, where each press's clutch/brake circuit requires dedicated pilot supply independent of adjacent presses.

Machine Tool and Industrial Automation

• Per-zone exhaust isolation on multi-axis machining center pneumatic manifolds, preventing exhaust back-pressure from high-flow coolant air-blow stations from affecting low-flow part presence sensor circuits in the same manifold.
• Supply galley isolation to enable scheduled preventive maintenance shutdown of one manifold zone while maintaining production on adjacent zones served by the same physical manifold body.

Food and Beverage Processing

• Creating clean-air supply zones isolated from standard air supply zones within a single ISO manifold on food packaging equipment, using blocking discs to separate food-contact actuator circuits from non-food-contact circuits.
• Pilot supply isolation for independently piloted valve stations on beverage filling machine manifolds where product contact valve pilots must be supplied from a regulated clean air source independent of the main manifold pilot galley.

General Industrial and OEM Machine Building

• Low-cost per-zone pressure isolation in multi-function machine manifolds as an alternative to physically separate manifold assemblies, reducing total manifold component count while achieving the same functional isolation.
• Manifold system design flexibility for OEM machine builders developing modular ISO manifold-based pneumatic systems, using blocking discs as a configurable feature of standardized manifold assemblies.

Ordering and Model Number Configuration

Blocking Discs and Port Isolation Kits are ordered by selecting the model number corresponding to the valve manifold standard and ISO size. Specify single disc or multi-disc kit as required.

For ISO 5599-1 W60/W64 Series single discs: Size 1 = 235A40; Size 2 = 236A40; Size 3 = 237A40.

For ISO 5599-1 W60/W64 Series 3-disc kits: Size 1 = 1007K77 ($79.75); Size 2 = 1008K77 ($95.75); Size 3 = 1009K77 ($112.00).

For ISO 5599-2 W65 Series blocking disc kits: Size 1 = 1376N77; Size 2 = 1378N77; Size 3 = 1380N77.

For ISO 15407 W66 Series main galley isolation kits (plug with O-ring): Size 00 = RD02BD0; Size 0 = RD01BD0.

For ISO 5599-2 W65 Series manifold port isolation kits: main galley = RPS4033CP; pilot galley Size 1 = RPS4032CP; Size 2 = RPS4132CP; Size 3 = RPS4232CP.

Blocking discs are inserted at the manifold station interface during manifold assembly. Consult the applicable manifold assembly instruction for correct disc placement and orientation.

Contact ROSS Controls at (800) 438-7677 for blocking disc availability for additional valve platforms including ANSI, SAE, and non-standard manifold configurations.

Related Products & Accessories

• ISO 5599-1 W60 and W64 Series Valves - ISO 5599-1 base-mounted valves for which 235A40/236A40/237A40 and 1007K77/1008K77/1009K77 blocking discs apply. https://www.rosscontrols.com/en/series
• ISO 5599-2 W65 Series Valves - ISO 5599-2 base-mounted valves for which 1376N77, 1378N77, and 1380N77 blocking disc kits apply. https://www.rosscontrols.com/en/series/243-iso-5599-2-w65-series
• Series 100 Manifold Blanking Kit - Blank station kits for sealing unused manifold positions on ISO valve manifolds. https://www.rosscontrols.com/en/series/100-manifold-blanking-kit
• Series 98 Interposed Regulators - Per-station pressure regulation for ISO valve manifolds. https://www.rosscontrols.com/en/series/98-interposed-regulators
• Series 99 Interposed Modules - Flow controls, pressure plates, and exhaust modules for ISO manifold stations. https://www.rosscontrols.com/en/series/99-interposed-modules
• 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: What does a blocking disc actually block?

A: A blocking disc closes a galley passage that runs through the manifold body between adjacent valve stations. These internal galleys carry the shared supply air (Port 1), shared exhaust A (Port 3), and shared exhaust B (Port 5) between all stations in the manifold assembly. Inserting a blocking disc at a station interface prevents air from flowing from one section of the manifold to the adjacent section through that specific galley channel.

Q: When would I need to use a blocking disc instead of separate manifolds?

A: Use a blocking disc when you want to create isolated pressure or exhaust zones within a single manifold assembly, saving the cost and complexity of designing separate manifolds. Blocking discs are appropriate when two or more stations share the same manifold body but require different supply pressures, different exhaust paths, or isolated pilot supplies. If complete mechanical separation between circuits is required, physically separate manifolds may be more appropriate.

Q: What is the difference between a single blocking disc and a three-disc kit?

A: A single blocking disc blocks one galley passage at the station interface, for example blocking only the supply galley (Port 1) while leaving the exhaust galleys (Ports 3 and 5) connected across the interface. A three-disc kit provides three discs to simultaneously block all three main galley passages (supply and both exhausts) at the same interface, creating complete main galley isolation between the two manifold sections at that point.

Q: Are blocking discs the same as manifold blanking kits?

A: No. A manifold blanking kit (Series 100) is used to seal an entire unused valve station position on the top surface of the manifold when no valve is installed. A blocking disc is inserted inside the manifold body at a station interface to block internal galley passages between two populated valve stations. They serve different purposes and are not interchangeable.

Q: Can blocking discs be used on ISO 15407 W66 Series manifolds?

A: Yes, but the form factor is different for ISO 15407 platforms. ISO 15407 W66 Series manifolds use plug-with-O-ring type port isolation kits (RD02BD0 for Size 00; RD01BD0 for Size 0) rather than flat discs. These plug kits serve the same purpose of isolating the main galley ports at a station interface.

Q: Can pilot port galleys also be blocked?

A: Yes. For ISO 5599-2 W65 Series manifolds, pilot galley isolation kits (RPS4032CP for Size 1; RPS4132CP for Size 2; RPS4232CP for Size 3) are available to block pilot galleys between stations, enabling independent pilot supply for manifold sections. This is used when different sections of the manifold require different pilot supply pressures or when one section uses external pilot and another uses internal pilot.

Q: Do blocking discs need to be removed for manifold maintenance?

A: Blocking discs installed in the manifold body do not typically need to be removed for routine maintenance unless the manifold is being reconfigured. During manifold disassembly for cleaning or station replacement, verify that blocking disc positions are documented so they can be reinstalled correctly. Check for disc condition (no cracks, no deformation) during any manifold disassembly.

Q: What materials are blocking discs made from?

A: ROSS does not publish specific material data for blocking discs in publicly available documentation. Contact ROSS Controls at (800) 438-7677 for material certification data if required for your application environment (e.g., food-grade, high-temperature, or corrosive exposure applications).

Q: How many blocking discs can be installed in one manifold assembly?

A: There is no inherent limit to the number of blocking disc positions in a manifold, subject to the number of station interfaces available (equal to the total number of stations minus one). Each station interface is an independent isolation point. In practice, a 10-station manifold could have up to 9 blocking disc positions, each independently configured to isolate or pass any combination of port galleys.

Q: What is the price of Blocking Disc kits?

A: Based on listed pricing, ISO 5599-1 three-disc kits range from $79.75 (Size 1 kit 1007K77) to $112.00 (Size 3 kit 1009K77). Contact ROSS Controls at (800) 438-7677 for current pricing on all single disc models and ISO 5599-2 and ISO 15407 kit variants.

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.
• Blocking discs are installed at the interface between two manifold stations during manifold assembly. Disassemble the manifold to the point where the target station interface is accessible.
• Insert the blocking disc(s) into the appropriate galley hole(s) at the station interface. The disc must be seated flush and fully in the galley bore to achieve effective port isolation.
• For plug-with-O-ring type isolation kits (ISO 15407 and ISO 5599-2), ensure the O-ring is seated properly in its groove before pressing the plug into the manifold port. Do not damage or twist the O-ring during installation.
• Reassemble the manifold stations and torque all mounting hardware to the specifications in the applicable valve series manifold assembly instruction.
• After assembly, gradually restore system pressure and verify port isolation by measuring the pressure at each supply inlet port on either side of the blocking disc. The pressures should be independent.
• Verify exhaust isolation by checking for airflow cross-talk between manifold exhaust ports on each side of the blocking location.
• Document the location and type of blocking discs installed in the manifold assembly drawing or maintenance records for future reference during manifold 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 complete model selection, manifold compatibility, and application assistance, visit rosscontrols.com or contact ROSS Controls at (800) 438-7677.