Remote Pilot Regulators High-Relief Full-Size Series Installation & Operating Instructions
Overview
ROSS Controls, founded in 1921 with over 100 years of leadership in fluid power, offers the Modular Remote High-Relief Pilot Regulators Full-Size Series as a specialized compressed air pressure regulation product for applications requiring high-capacity overpressure relief in addition to remote pressure adjustment. These self-relieving diaphragm regulators deliver flows up to 150 scfm and provide an outlet pressure range up to 200 psig (0 to 14 bar), controlled by a remote pilot regulator installed at a location separate from the main valve body.
The High-Relief designation indicates that the relief capacity of this design is greater than the standard Full-Size Series, making it appropriate for applications where downstream pressure can spike rapidly and must be quickly relieved. A control regulator (ordered separately) adjusts the outlet pressure of the pilot-operated regulator. Any M/P regulator can be used as the pilot. Overpressure is relieved through the exhaust port when pressure on the top of the diaphragm exceeds the pilot pressure on the bottom.
Filters must be installed immediately upstream of the regulator to ensure a clean supply of air. For technical support, contact ROSS at 1-800-GET-ROSS or visit www.rosscontrols.com.
Key Features
High-Relief Capacity Overpressure Protection
The High-Relief Full-Size Series is designed for applications where downstream pressure transients are frequent or of large magnitude. The enhanced relief capacity vents downstream overpressure through the exhaust port more rapidly than a standard diaphragm regulator, protecting downstream equipment and maintaining process stability. Fluororelastomer seals are available as an option for elevated temperature or chemical compatibility requirements — consult ROSS for details.
Extended Outlet Pressure Range to 200 psig
With an adjustable outlet pressure range from 0 to 200 psig (0 to 14 bar), this series covers applications that exceed the 125 psig ceiling of the standard Full-Size regulator. This makes the High-Relief model suitable for higher-pressure pneumatic circuits including press tools, clamp cylinders, and intensifier supplies.
Optional Fluororelastomer Seals
Standard seals are nitrile, compatible with most compressed air applications. Optional fluororelastomer seals are available for environments requiring elevated chemical resistance or higher operating temperatures. Consult ROSS Controls when specifying High-Relief regulators for non-standard fluid media or extreme temperature conditions.
Technical Specifications
- Construction: Diaphragm, self-relieving (high-relief capacity)
- Maximum Flow: 150 scfm
- Ambient/Media Temperature: 40° to 175°F (4° to 80°C)
- Fluid Media: Compressed air
- Inlet Pressure: 300 psig (21 bar) maximum
- Outlet Pressure: Adjustable 0 to 200 psig (0 to 14 bar)
- Pilot Ports: 1/4 NPTF
- Pressure Gauge: 0 to 200 psig (0 to 14 bar); 1/4 NPT gauge ports front and rear
- Body and Dome: Zinc
- Seals: Nitrile standard; Fluororelastomer optional
- Valve: Brass; Valve Cap: Nylon
- Port Sizes: 1/4, 3/8, 1/2, 3/4 inch NPT
- Head Kit Part Numbers: R-KA37-01-1/4, R-KA37-01-3/8, R-KA37-01-1/2, R-KA37-01-3/4
- Gauge port wall bracket: R-KA37-68; Extended bracket: R-KA37-68L
Applications
Press Tools and Clamp Cylinders
Hydraulic and pneumatic press tools, clamp cylinders, and forming equipment often generate rapid pressure spikes when work cycles complete or tooling contacts a hard stop. The High-Relief Full-Size Series effectively manages these transients, preventing overpressure damage to actuators and valves downstream while maintaining consistent cycle-to-cycle pressure delivery.
Process Equipment with Variable Demand
Processes with variable air demand — such as filling, packaging, and sealing machines — benefit from the high-relief design because outlet pressure remains stable across sudden demand changes. The remote pilot configuration allows operators to adjust supply pressure from a control panel, improving process flexibility and reducing the time needed for pressure adjustments during product changeovers.
Safety and Compliance Standards
All pneumatic installation and service work must be performed by qualified personnel following applicable lockout/tagout procedures per OSHA 29 CFR 1910.147. Exhaust the system completely before service. Do not exceed the rated inlet pressure of 300 psig. Observe all CAUTIONS and WARNINGS provided in the full PDF documentation. Contact ROSS if fluororelastomer seal compatibility with a specific fluid must be verified.
Installation and Setup Guide
Installation Procedure
- Step 1: Depressurize and lock out all upstream air pressure.
- Step 2: Install a 5-micron-rated upstream filter immediately ahead of the regulator.
- Step 3: Install the main regulator near the downstream device; observe flow direction arrow.
- Step 4: Install the pilot regulator at a remote, convenient location.
- Step 5: Connect a pilot supply line from the pilot regulator to the 1/4 NPTF pilot port.
- Step 6: Install pressure gauges or plugs in the front and rear gauge ports.
- Step 7: Re-pressurize and adjust the pilot regulator to the desired outlet pressure.
- Step 8: Verify high-relief operation by incrementally exceeding setpoint and observing exhaust port relief.
Maintenance Guidance
If the air supply is kept clean, the regulator will provide extended service. Erratic operation or loss of regulation usually indicates dirt in the valve seat or a leaking seal. Shut off air supply, exhaust trapped air, and clean the valve seat with soap and water. Replace worn valve and seal components with appropriate ROSS repair kits. Do not remove the dome; return to ROSS for dome-related repairs.
Why Choose ROSS Controls
ROSS Controls, founded in 1921 with over 100 years of leadership in fluid power, designs and manufactures pneumatic air preparation products to the highest standards of quality and reliability. The High-Relief Full-Size Series is part of ROSS's comprehensive regulator portfolio, supported by ROSS's global distribution network and technical service team available at 1-800-GET-ROSS or www.rosscontrols.com.
Download This Document
PDF download: https://ross-admin-global-us-east.s3.amazonaws.com/production/uploads/document_language_file/file/198/ROSS_Regulator_Modular_Remote-Pilot_High-Relief_Full-Size_Series_SS-R014.pdf
Related Products and Resources
- Remote Pilot Regulators Full-Size Series (SS-R013)
- Remote Pilot Piston Regulators MD4 Series (SS-R016)
- Regulators Bantam Series (SS-R001)
- ROSS Air Preparation Catalog — www.rosscontrols.com
Frequently Asked Questions
Q: What distinguishes the High-Relief model from the standard Full-Size regulator?
A: The High-Relief model has greater overpressure relief capacity, venting downstream pressure more rapidly through the exhaust port. It also offers an outlet range up to 200 psig versus 125 psig for the standard model.
Q: Are fluororelastomer seals available?
A: Yes. Fluororelastomer seal options are available for chemical resistance or elevated temperature applications. Consult ROSS Controls when ordering.
Q: What is the maximum inlet pressure?
A: 300 psig (21 bar) maximum.
Q: What is the outlet pressure range?
A: Adjustable from 0 to 200 psig (0 to 14 bar) via the remote pilot regulator.
Q: What flow rate does the High-Relief Full-Size Series support?
A: Up to 150 scfm.
Q: Can any regulator be used as the remote pilot?
A: Yes — any M/P regulator can serve as the pilot. The pilot may be installed some distance from the main regulator.
Q: What is the operating temperature range?
A: 40° to 175°F (4° to 80°C) for both ambient and media temperatures.
Q: What port sizes are available?
A: 1/4, 3/8, 1/2, and 3/4 inch NPT.