Inline Slim-Line Valves [95 Series] Solenoid & Air Pilot Spool Valve

Product Overview

The ROSS Controls 95 Series is a family of slim-line, body-ported directional control valves designed for pneumatic systems where installation space is limited but flow performance cannot be compromised. Available in 3/2, 5/2, and 5/3 valve functions with solenoid or air pilot actuation, these spool-construction valves accept port sizes from 1/8 to 1/2 inch and deliver flow coefficients from 0.7 Cv (1/8 port, 5/3 function) up to 4.5 Cv (1/2 port, 5/2 function). Both inline mounting and multi-station manifold assembly are supported, giving system designers flexibility to adapt the valve to the machine layout rather than the reverse.

The 95 Series uses resilient seal spool construction throughout. The spool and sleeve geometry maintains positive sealing with low shift force requirements, supports both lubricated and non-lubricated compressed air service, and tolerates the level of contamination typical in general industrial environments. All solenoid models carry an IP65 enclosure rating and are available in 24 VDC or 110/120 VAC, with continuous duty solenoids consuming 2.5 watts DC or 3.5 to 3.6 VA holding on AC. All models include a non-locking pushbutton manual override standard for setup and troubleshooting.

For 5/2 and 5/3 functions, the 95 Series is available in both single solenoid (spring return) and double solenoid (detented) configurations, as well as corresponding single-pilot and double-pilot air-controlled variants. The 5/3 double solenoid spring-center valves are offered with closed-center, open-center, and pressure-center positions to support holding, exhaust, or pressure-balance mid-position requirements. A 5/2 NAMUR interface variant with a 1/4 inch port is also available for direct actuator mounting per VDI/VDE 3847.

The 95 Series mounts inline in any orientation. When manifold-assembled, common supply and exhaust passages eliminate individual piping runs for each valve station, reducing installation labor and system footprint. Multi-station manifold blocks are available for both 3/2 and 5/2 or 5/3 valve configurations, enabling integrated valve banks of two to ten stations. For design engineers specifying pneumatic components in space-constrained automation, the 95 Series delivers a practical combination of spool reliability, broad function coverage, and straightforward electrical and pneumatic interface options.

Key Engineering Features

• Resilient Seal Spool Construction - The spool and sleeve design uses resilient seal elements that maintain positive sealing against port faces, providing reliable directional control with low internal leakage across millions of cycles in both lubricated and non-lubricated air service.
• Slim-Line Compact Body - The narrow valve body profile minimizes the space claim in panel enclosures, machine frames, and manifold banks. A 1/8 port 5/2 single solenoid model measures approximately 4.33 inches (110 mm) in length, enabling dense valve grouping in space-constrained installations.
• Inline and Manifold Mounting - All 95 Series valves mount inline using body port connections in NPT or G (BSPP) threads. The same valve body also accepts manifold base mounting, allowing system designers to build integrated multi-station valve banks with common supply and exhaust passages without changing the valve.
• Broad Function Coverage - The series covers 3/2 (normally closed and normally open, spring return), 5/2 (single solenoid spring return and double solenoid detented), and 5/3 (closed center, open center, pressure center, spring centered) functions in both solenoid and air pilot actuation types.
• Port Sizes 1/8 through 1/2 Inch - Four port sizes (1/8, 1/4, 3/8, and 1/2 inch) span a Cv range from 0.7 to 4.5, letting engineers match valve flow capacity precisely to actuator volume and required cycle speed without significant oversizing.
• High Flow Capacity for Body Size - The optimized internal spool geometry delivers up to 4.5 Cv in a 1/2 inch port body. This flow-to-body-size ratio makes the 95 Series suitable for cycling medium-bore cylinders at speeds typical of packaging and assembly automation.
• 24 VDC and 110/120 VAC Solenoid Options - Standard solenoid voltages of 24 VDC and 110/120 VAC cover the majority of North American and global control system architectures. AC solenoids are rated at 3.5 to 3.6 VA holding; DC solenoids consume 2.5 watts. All solenoids are rated for continuous duty.
• IP65 Solenoid Enclosure - The IP65 enclosure rating (IEC 60529) on all solenoid models provides dust-tight protection and resistance to low-pressure water jets, supporting deployment in typical industrial and light washdown environments.
• Non-Locking Pushbutton Manual Override - Every 95 Series valve includes a non-locking manual override as standard. The override allows manual shifting for commissioning, electrical troubleshooting, or system verification without requiring energized solenoids or pilot air supply.
• NAMUR Interface Option - A dedicated 5/2 NAMUR interface variant (1/4 inch port, Cv 1.3) enables direct mounting to pneumatic actuators per VDI/VDE 3847, eliminating external tubing and fittings for a compact valve-to-actuator assembly.

Technical Specifications

General Specifications

Temperature Ratings

Operating temperature range applies to both ambient and media conditions for all 95 Series configurations.

Electrical Data (Solenoid Pilot Valves)

All solenoids are rated for continuous duty with an IP65 enclosure rating per IEC 60529. Electrical connections vary by port size.

Electrical Connection Options

Flow Performance Data

Flow performance data for primary solenoid and air pilot controlled configurations. Voltage suffix W = 24 VDC, Z = 110-120 VAC 50/60 Hz. For BSPP threads, add D prefix (e.g., D9576K3001W).

Certifications & Compliance

Typical Applications & Industries

Packaging and Material Handling

• Form-fill-seal machinery, cartoning lines, and case packing systems where multiple cylinders must be controlled within compact machine frames. The 95 Series manifold option consolidates valve stations and eliminates individual pneumatic tubing runs, reducing assembly time and maintenance access points.
• Pick-and-place, gripper, and clamping circuits on automated transfer systems where fast, repeatable shifting of small-bore to medium-bore cylinders is required. The 5/2 single solenoid spring return function provides inherent fail-to-retract behavior for product release applications.
• Labeling, coding, and high-speed reject systems that benefit from the compact body size and high Cv-to-port-size ratio of the 95 Series, enabling fast cylinder response in tight panel or machine-integrated installations.

Automotive Assembly and Body Shop

• Weld fixture clamping, lift-and-transfer units, and assembly tooling where a high density of pneumatic actuators must be controlled within defined machine envelope constraints. Manifold-mounted 95 Series banks support centralized valve placement with common supply and exhaust.
• Body-in-white handling systems and door assembly fixtures requiring bidirectional cylinder control with detented or spring-return behavior depending on safety and fail-state requirements.
• Test and leak-check stations where 5/3 closed-center or pressure-center functions are needed to isolate actuator ports in the mid-position for pressure hold or pressure balance sequences.

Food and Beverage Processing

• Filling, capping, and bottling lines where lube-free air service is preferred to avoid product contamination risk. The 95 Series spool construction is compatible with non-lubricated compressed air at 22.5 to 150 psig.
• Conveyor divert gates, reject pushers, and accumulation control systems benefiting from compact valve mounting integrated into conveyor frame structures where space for inline valve plumbing is minimal.
• Packaging and tray-sealing equipment operating in moderate washdown environments, supported by the IP65 solenoid enclosure rating on all electrical models.

General Industrial Automation

• Machine tool pneumatic circuits including workpiece clamping, chip blowing, pallet location pins, and door or guard interlocks requiring reliable directional control within control cabinet or manifold enclosures.
• Pneumatic press and stamping auxiliary circuits for part ejection, blank feeding, and scrap removal where multiple functions must be grouped in a limited valve panel area.
• Material handling and sortation systems, including pusher bars, pop-up rollers, and divert arms, where the 5/2 detented function retains the last commanded position during momentary power interruption without requiring a continuous solenoid signal.

Process Automation and Actuator Control

• Control of pneumatic quarter-turn actuators on ball valves and butterfly valves using the NAMUR interface 5/2 variant, which mounts directly to the actuator per VDI/VDE 3847 without external tubing or brackets.
• Remote pneumatic actuator control in process plants where the air pilot (pressure-controlled) variants are preferred in electrically sensitive areas or where signal air is already available from a process controller.
• Pilot valve duty in larger valve island assemblies where the compact 95 Series body size is appropriate for controlling pilot-operated main stage valves with modest flow requirements.

Ordering and Model Number Configuration

The ROSS 95 Series uses a structured model number system that encodes valve function, port size, actuation type, center position (5/3 only), voltage, and thread type. Standard NPT threads are default; add D prefix for BSPP/G threads. Insert voltage suffix W for 24 VDC or Z for 110-120 VAC 50/60 Hz.

Voltage codes apply to solenoid-controlled models only: W = 24 VDC; Z = 110-120 VAC, 50/60 Hz. Air pilot (pressure-controlled) models have no voltage suffix.

For BSPP (G) thread ports, add the D prefix before the model number (e.g., D9576K3001W instead of 9576K3001W).

Solenoid electrical connection type is determined by port size: 1/8 port models use MICRO-MINI EN 175301-803 connectors; 1/4, 3/8, and 1/2 port models use EN 175301-803 Industrial Form B connectors.

Valves are available with factory-installed prewired connectors; consult ROSS Controls for prewired connector options.

5/3 spring-center function codes: 019 = Pressure (power) center; 010 = Closed center; 007 = Open center.

NAMUR interface models (9576K290x series) use 1/4 inch port only and mount per VDI/VDE 3847. Signal port thread for 10-32 UNF applies to select small port sizes; 1/8 inch NPT signal port applies to larger port sizes.

Accessories

Electrical Connectors

ROSS offers standalone and prewired solenoid connectors for 95 Series valves. Options include IP65 coil connectors and connectors with integrated LED status indicators and surge suppressors.

Manifold Blocks

Multi-station manifold blocks are available for 3/2 valves and for 5/2 or 5/3 valves, supporting two to ten valve stations with common supply and exhaust passages. Manifold mounting eliminates individual inline piping runs for each station, reduces system footprint, and simplifies maintenance. Contact ROSS Controls for manifold station count and porting configuration options.

Sub-Bases

Individual sub-bases convert the 95 Series inline body-port connections to bottom-ported configurations for simplified panel or plate-mount piping in installations where top or side port access is not preferred.

Related Products & Accessories

• NAMUR Interface Valves (95 and 34 Series) - NAMUR-interface 5/2 variants of the 95 Series for direct actuator mounting per VDI/VDE 3847, and the 34 Series ball-poppet compact NAMUR valve for harsh or washdown environments. https://www.rosscontrols.com/en/documents/9/namur-interface-valves-95-34-series
• 21 Series Classic Inline Poppet Valves - Inline poppet directional control valves in 2/2, 3/2, and 4/2 functions with port sizes 1/4 to 1-1/2 inch and Cv up to 33 for higher flow requirements than the 95 Series. https://www.rosscontrols.com/en/series/231-low-high-temperatures-classic-21-series
• 27 Series Classic Inline Poppet Valves - High-flow inline poppet valves with port sizes up to 2-1/2 inch and Cv up to 70 for large actuator and high-flow pneumatic circuits. https://www.rosscontrols.com/en/series/230-standard-temperatures-classic-27-series
• CP and LF Series Individual Solenoid Valve Manifolds - Standard pressure solenoid valve manifolds in 2-way and 3-way configurations for high-flow manifold applications where higher Cv per station than 95 Series is required. https://www.rosscontrols.com/en/series/234-standard-pressure-cp-lf-series
• 16 Series Compact Directional Control Valves - Compact spool valves with solenoid or air pilot actuation for smaller actuator control requirements where the 95 Series port range begins at the upper end of the application requirement. https://www.rosscontrols.com/en/documents/10/16-series-compact-valves
• Electrical Connectors - DIN and MICRO-MINI connectors, prewired assemblies, and lighted indicator versions for ROSS solenoid valves including 95 Series models. https://www.rosscontrols.com/en/series/91-electrical-connectors

Frequently Asked Questions (FAQ)

Q: What is the difference between the ROSS 95 Series spool valve and the 21 or 27 Series poppet valves?

A: The 95 Series uses spool-and-sleeve construction, where a sliding spool with resilient seals redirects airflow between ports. The 21 and 27 Series use poppet construction, where perpendicular face seals provide positive shutoff and near-zero internal leakage. The 95 Series is optimized for compact, multi-function directional control (3/2, 5/2, 5/3) in smaller port sizes up to 1/2 inch, while the 21 and 27 Series cover larger port sizes (up to 1-1/2 and 2-1/2 inch respectively) with higher Cv values. For 5-port directional control of standard bore cylinders in space-constrained packaging and assembly equipment, the 95 Series is the more appropriate choice.

Q: What valve functions are available in the 95 Series?

A: The 95 Series covers 3/2 normally closed and normally open with spring return, 5/2 single solenoid spring return, 5/2 double solenoid detented (memory), 5/3 double solenoid spring center in closed-center, open-center, and pressure-center positions, and air pilot equivalents for all of these functions. A 5/2 NAMUR interface variant is also available for direct actuator mounting. This covers the majority of standard directional control requirements for single-acting and double-acting pneumatic cylinder circuits.

Q: What is the maximum Cv available in the 95 Series?

A: The maximum Cv is 4.5, available in the 1/2 inch port 5/2 spring return and 5/2 detented solenoid models (9576K4001 and 9576K4002 series) and in the 1/2 inch port 5/3 double solenoid spring center model (9577K4019, 9577K4010, 9577K4007 series). The 5/3 double pilot pressure-controlled model in 1/2 inch port reaches a maximum of 3.4 Cv. For 3/2 function, maximum Cv is 2.6 in the 3/8 inch port configuration.

Q: Can the 95 Series valve be used without air line lubrication?

A: Yes. The 95 Series is rated for both lubricated and non-lubricated (lube-free) compressed air service. If lubrication is introduced at startup, it should be continued throughout the valve's service life, as removing lubrication from a previously lubricated system can cause accelerated seal wear. For applications where product contamination risk makes lubrication undesirable, specifying a non-lubricated installation from the start is recommended.

Q: What is the operating pressure range?

A: Most 95 Series valve configurations operate from 22.5 to 150 psig (1.5 to 10 bar). The 5/3 spring-center functions (double solenoid and double pilot) require a minimum inlet pressure of 30 psig (2 bar) to ensure reliable spring-centering against the pilot force. The maximum for all configurations is 150 psig (10 bar).

Q: What electrical voltages and connector types are available for solenoid models?

A: Standard voltages are 24 VDC (2.5 watts, suffix W in model number) and 110/120 VAC 50/60 Hz (3.5 to 3.6 VA holding, suffix Z). The solenoid connector type is determined by port size: 1/8 inch port models use a MICRO-MINI EN 175301-803 connector; 1/4, 3/8, and 1/2 inch port models use an EN 175301-803 Industrial Form B connector. All solenoids are rated for continuous duty with an IP65 enclosure rating.

Q: What does the detented (double solenoid) function mean in practice?

A: In a detented or memory function (double solenoid or double pilot), the valve shifts when a signal is applied to one solenoid or pilot port and holds that position mechanically after the signal is removed, without requiring continuous power or air. It returns to the original position only when a signal is applied to the opposite solenoid or pilot port. This is useful in applications where the actuator must remain in a commanded position during a power cycle or where continuous solenoid power consumption is undesirable.

Q: How do the three 5/3 center position options differ?

A: Closed-center (function code 010) blocks all five ports when the valve is in the spring-centered position, holding actuator load in place. Open-center (function code 007) blocks the inlet port and connects both actuator ports to exhaust, allowing the actuator to float freely. Pressure-center or power-center (function code 019) connects the inlet to both actuator ports, balancing pressure on both sides of a double-acting cylinder for applications needing mid-position pressure equalization or cylinder cushioning.

Q: What pilot pressure is required for air pilot (pressure-controlled) 95 Series models?

A: Pilot pressure must be equal to or greater than inlet pressure. The pilot supply is external on all 95 Series air pilot models, meaning a separate pilot signal line must be connected to the signal port. Signal port thread sizes are 10-32 UNF for 1/8 inch port configurations and 1/8 inch NPT for 1/4, 3/8, and 1/2 inch port configurations.

Q: Are NPT and BSPP thread options both available?

A: Yes. Standard models use NPT threads. To order with BSPP (G) ISO parallel threads, add a D prefix to the model number. For example, D9576K3001W is the BSPP equivalent of the NPT model 9576K3001W. This applies to all solenoid-controlled and air pilot-controlled 95 Series variants.

Q: How does the NAMUR interface variant mount to a pneumatic actuator?

A: The NAMUR interface 5/2 variant (9576K290x series) mounts directly to the actuator's NAMUR interface face per VDI/VDE 3847, using a standardized bolt pattern and O-ring sealed port alignment. This eliminates external tubing between the valve and actuator, reduces the overall assembly footprint, and speeds installation. O-rings must be placed in the actuator interface grooves before mounting; correct O-ring seating should be verified before applying inlet pressure.

Q: What manifold configurations are available for the 95 Series?

A: Multi-station manifold blocks are available for both 3/2 valves and for 5/2 or 5/3 valves, with common supply and exhaust passages running through the manifold body. Individual valve stations are serviced without disrupting adjacent stations. Manifold configurations support two or more stations. Contact ROSS Controls for the specific station count and porting options available for a given application requirement.

Q: What is the ambient temperature range for the 95 Series?

A: All 95 Series configurations are rated for ambient and media temperatures from 41 to 140 F (5 to 60 C). This covers the majority of standard industrial environments. The 95 Series is not designed for extreme low or high temperature service. For applications requiring operation below 41 F or above 140 F, the ROSS 21 Series with Buna-N or Fluorocarbon seals should be considered.

Q: Are CAD models available for the 95 Series?

A: Yes. Downloadable CAD models are available for 95 Series valve variants through the ROSS Controls website at rosscontrols.com. These support integration into SolidWorks, AutoCAD, and other major CAD platforms for dimensional verification, interference checking, and machine documentation.

Q: What is the expected lead time for 95 Series valves?

A: Standard manufacturing lead times for quantities of 10 or fewer units are typically 3 to 4 weeks. Many 95 Series standard configurations are stocked for faster delivery. Contact ROSS Controls at (800) 438-7677 or through rosscontrols.com for current stock availability and lead time for specific model numbers.

Installation & Maintenance Guidelines

• Mount the valve inline in any orientation. There is no preferred mounting direction restriction for the 95 Series; the valve can be installed vertically, horizontally, or inverted depending on the machine layout.
• Supply filtered compressed air to the valve inlet. Filtration to a maximum particle size of 40 microns is recommended to prevent spool and seal contamination that could cause erratic shifting or accelerated wear. Finer filtration (5 microns) extends service life further.
• Verify that inlet pressure is within the 22.5 to 150 psig (1.5 to 10 bar) operating range before applying pressure. For 5/3 spring-center functions, minimum inlet pressure is 30 psig (2 bar) to ensure reliable centering.
• For air pilot (pressure-controlled) models, connect the pilot signal to the signal port. Pilot pressure must be equal to or greater than inlet pressure. Do not apply pilot pressure below inlet pressure, as this may cause incomplete or unreliable valve shifting.
• Do not restrict the exhaust ports. Back pressure at the exhaust port can prevent full valve shifting and cause sluggish or erratic operation. If exhaust silencers are used, verify that the silencer flow capacity is at least equal to the valve exhaust capacity.
• For solenoid models, verify coil voltage matches the supply voltage before energizing. Apply 24 VDC to W-suffix models and 110-120 VAC 50/60 Hz to Z-suffix models. Applying incorrect voltage will damage the solenoid coil.
• Connect the solenoid to the control circuit through the connector appropriate for the port size: MICRO-MINI EN 175301-803 for 1/8 inch port models; EN 175301-803 Industrial Form B for 1/4, 3/8, and 1/2 inch port models. Ensure connector locking screws or latches are fully engaged to maintain IP65 integrity.
• Test manual override function before applying solenoid power or pilot air. Depress the non-locking pushbutton override to verify that the valve shifts and that connected actuators respond correctly. Release the override button before resuming normal electrical or pneumatic control.
• For NAMUR interface models, place the O-rings provided in the actuator interface grooves before mounting the valve. Align the valve port pattern with the actuator NAMUR face ports per VDI/VDE 3847 and torque mounting fasteners to the actuator manufacturer's specification. Verify O-ring seating visually before pressurizing the system.
• When assembling 95 Series valves onto a manifold block, verify that the valve body seating surface and manifold interface are clean and free of burrs or debris before installation. Torque manifold mounting screws evenly to avoid distortion of the valve body seating surface.
• If non-lubricated air service is intended, do not introduce lubrication oil during initial startup. If lubrication is introduced at any point, maintain it continuously. Removing lubrication after lubricated operation has begun accelerates seal wear.
• After installation, apply full system pressure and cycle the valve several times using the manual override or control signal. Inspect all port connections and manifold joints for air leaks using a leak detection solution or electronic leak detector before returning the system to production.

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 Controls offices in the USA (headquarters in Ferndale, Michigan), Canada, Brazil, Germany, France, United Kingdom, India, China, and Japan.

Contact ROSS Controls USA at (800) 438-7677 or visit rosscontrols.com for product configuration, technical support, and distributor locator services.

For complete technical data, dimensional drawings, model number configurator, and CAD model downloads, visit the ROSS Controls 95 Series product page at rosscontrols.com/en/series/236-inline-slim-line-valves-95-series.

Download Catalog: https://www.rosscontrols.com/en/documents/8?filename=Directional_Control_Slim-Line_Valves_95_Series_ROSS-SL-95_EN.pdf