Full-Size Series Port Sizes 1/4" to 3/4"; Flow to 155 scfm (4490 l/min)

Product Overview

The ROSS Controls Full-Size Series is a family of modular and inline air preparation filters designed for port sizes 1/4 inch through 3/4 inch (NPT or G/BSPP) with maximum particulate filter flow of 155 scfm (4,490 l/min). The Full-Size Series is engineered for higher-demand pneumatic systems where the Mid-Size Series flow capacity is insufficient, providing the next tier of filtration performance in the ROSS FRL product line while maintaining the same 1/4-to-1/2-inch port coverage plus expanding to 3/4-inch ports.

The Full-Size Series encompasses particulate filters, coalescing filters, and oil vapor removal configurations. Particulate filter models use 5-micron polyethylene (standard) elements, with 20-micron and 40-micron sintered bronze options. Coalescing filter variants using borosilicate glass fiber elements handle oil aerosols at 0.3-micron (standard) or 0.01-micron levels in standard or extended bowl configurations. Both modular and inline mounting options are supported, with modular configurations enabling assembly of multi-stage FRL stations using ROSS port kits.

The standard bowl is high-strength polycarbonate protected by a steel shatterguard for personnel protection, with an 8-oz (240-ml) capacity. The metal bowl option is zinc with a clear nylon sight glass, extending upper operating temperature to 175 F (79 C) and maximum inlet pressure to 200 psig (14 bar). Drain options include internal automatic drain and manual drain, with an internal float drain option available on select configurations.

The Full-Size Series is the recommended choice for general industrial compressed air systems at 3/4-inch port sizes or for 1/4-to-1/2-inch systems where the 155 scfm flow capacity is required to maintain acceptable pressure drop in high-demand applications.

Key Engineering Features

• High Flow to 155 scfm at Port Sizes Through 3/4 Inch - Provides 155 scfm (4,490 l/min) flow capacity at 100 psig inlet, serving larger pneumatic systems including assembly machine main supply headers, central FRL stations, and high-cycle actuator groups.
• Port Sizes from 1/4 to 3/4 Inch - Extends coverage beyond the Mid-Size and MD3 Series to include 3/4-inch NPT and BSPP ports, enabling use on main compressed air supply lines serving production equipment and actuator groups.
• Modular and Inline Mounting - Both modular manifold station and direct pipeline inline mounting options are supported. Modular configurations build multi-component FRL stations from a common manifold with single inlet and outlet connections.
• Steel Shatterguard Polycarbonate Bowl - Standard polycarbonate bowl (8-oz / 240-ml) is protected by a steel shatterguard that contains bowl fragments in the event of impact, providing upgraded personnel and equipment protection compared to unshielded bowls.
• Zinc Metal Bowl with Nylon Sight Glass - Zinc metal bowl (8-oz / 240-ml) option extends upper operating temperature to 175 F (79 C) and maximum inlet pressure to 200 psig (14 bar). The clear nylon sight glass allows visual liquid level monitoring without full bowl transparency.
• 5-Micron, 20-Micron, and 40-Micron Particulate Filtration - Standard 5-micron polyethylene element. Optional 20-micron and 40-micron sintered bronze elements for coarser-cut prefiltration stages or applications with high upstream contamination levels.
• Coalescing Filter Option (0.3 and 0.01 Micron) - Coalescing variants using borosilicate glass fiber elements in standard (8-oz) or extended (20-oz) aluminum bowls remove oil aerosols to ISO 8573-1 Class 2 (0.3 micron) or Class 1 (0.01 micron) oil content levels.
• Internal Automatic and Manual Drain Options - Automatic internal drain purges condensate without operator intervention. Manual drain provides controlled purging. Internal float drain option available on select configurations for high condensate accumulation rates.
• Integrated Differential Gauge Slide - Coalescing filter variants include a small differential pressure gauge slide for element condition monitoring. Particulate filter variants use separate gauge options.
• NPT and G (BSPP) Thread Availability - Both NPT and G (BSPP) thread types are standard catalog options for international machine design compatibility.

Technical Specifications

General Specifications

Temperature Ratings

Temperature ratings are determined by bowl material. Polycarbonate with steel shatterguard operates at lower temperatures than zinc metal bowl.

Important: Do not use polycarbonate bowls in environments with solvents, strong cleaning agents, or other chemicals incompatible with polycarbonate. Select the zinc metal bowl option for elevated temperature or chemical exposure environments.

Flow Performance Data

Flow performance at 100 psig inlet pressure, new element. Coalescing filter standard bowl (100 scfm) and extended bowl flows may differ.

Certifications & Compliance

Typical Applications & Industries

Manufacturing Plant Compressed Air Distribution

• Main compressed air supply header filtration at 3/4-inch port drops serving pneumatic machine tools, actuator groups, and production line equipment where 155 scfm capacity accommodates simultaneous high-cycle demand from multiple actuators.
• Branch header air preparation for assembly workstations, pallet assembly lines, and manufacturing cells where the 3/4-inch Full-Size Series filter serves the entire cell supply before individual machine FRL units.
• Air preparation for large pneumatic cylinders (bore 3 to 6 inches), pneumatic press circuits, and forming actuators where flow demand at 3/4-inch port size exceeds Mid-Size and MD3 Series capacity.
• Central FRL station on rolling carts and portable utility stations providing filtered, regulated air at workstation drops for maintenance and repair operations throughout a production facility.

Automotive and Heavy Industry Assembly

• Main supply air preparation for robot cell headers, transfer press pneumatics, and automated assembly systems where multiple robots and actuators demand combined flows up to 155 scfm from a common 3/4-inch supply.
• Welding line air preparation for pneumatic clamp and locate fixtures, weld gun cylinders, and part transfer systems on automotive body assembly lines.
• Air preparation for press brake, stamping, and forming machine pneumatics where 3/4-inch supply lines and 155 scfm capacity accommodate high-speed, high-frequency actuation cycles.
• Underbody assembly and chassis assembly pneumatics where overhead-mounted Full-Size Series filters serve hanging air supply drops at multiple workstations on a common supply rail.

Process Industries and Utilities

• Instrument air supply header filtration at 3/4-inch port manifolds in process plants serving multiple pneumatic positioners, valve actuators, and instrument supply drops.
• Compressed air preparation for pneumatic actuators on large process valves, dampers, and louvers in power generation, oil and gas, and chemical plant environments.
• Air preparation ahead of compressed air-operated diaphragm pumps in process chemical transfer where 5-micron filtration protects pump actuator internals from pipe scale and particulate.
• Coalescing filter (0.01-micron) in process plant instrument air systems where reciprocating compressor oil carryover at 3/4-inch supply headers threatens downstream instrument reliability.

Woodworking, Plastics, and General Manufacturing

• Main supply air preparation for CNC router and machining center pneumatics at 3/4-inch port supply lines, where 155 scfm capacity accommodates vacuum pump assist, tool change, and workholding circuits simultaneously.
• Air preparation for blow-molding machine air circuits where large-diameter cylinders and high-volume air blast requirements demand 3/4-inch filtered supply at high flow.
• Compressed air supply for pneumatic conveyors, pneumatic transport systems, and air slide conveyors where continuous high-volume air flow through 3/4-inch supply connections requires reliable particulate filtration.
• Air preparation for spray painting, coating, and surface treatment equipment where consistent air quality at the supply header reduces product defects from oil or particulate contamination.

Ordering and Model Number Configuration

The ROSS Full-Size Series uses a structured model number system encoding port size, drain type, bowl material, and mounting configuration. Example model numbers are listed below. Prefix C for G (BSPP) thread models.

For G (BSPP) threads, add the prefix C to the model number (e.g., C5021B2008 for 1/4 G, auto drain, polycarbonate).

Coalescing filter models and inline variants use separate model number codes; consult the ROSS FRL catalog for full selection.

Internal float drain option available; contact ROSS Controls for applicable model number.

The 939K77 (5-micron) replacement element is specific to the Full-Size Series and is not interchangeable with Bantam, Miniature, or Mid-Size elements.

Coalescing standard bowl replacement elements: 947K77 (0.3 micron), 948K77 (0.01 micron). Extended bowl elements use separate part numbers.

Accessories

Replacement Filter Elements

ROSS replacement filter elements for Full-Size Series. Elements are specific to Full-Size and are not interchangeable with other series elements.

Port Kits and Manifold Hardware

Port kits for Full-Size Series enable modular FRL station assembly. Multiple port kit options accommodate different port sizes and numbers of stations. Consult ROSS Controls for specific port kit model numbers.

Related Products & Accessories

• MD3 Series Air Preparation Filters - Advanced modular filters for 1/4 to 1/2 port sizes with flow to 92 scfm, diaphragm regulator, and L-O-X lockout integration. https://www.rosscontrols.com/en/series/72-md3-series
• MD4 Series Air Preparation Filters - Larger-bore MD4 for 3/8 to 3/4 port sizes with flow to 204 scfm and clean air package options. https://www.rosscontrols.com/en/series/73-md4-series
• High Capacity Series Air Preparation Filters - Inline filters for 3/4 to 2-inch port sizes with flow to 1,000 scfm for main supply headers. https://www.rosscontrols.com/en/series/71-high-capacity-series
• Mid-Size Series Air Preparation Filters - Proven modular filters for 1/4 to 1/2 port sizes with flow to 75 scfm. https://www.rosscontrols.com/en/series/76-mid-size-series
• L-O-X Lockout Valves - OSHA-compliant pneumatic lockout valves for energy isolation during maintenance. https://www.rosscontrols.com/en/series/1287-lockout-valves-15-series

Frequently Asked Questions (FAQ)

Q: What is the maximum flow capacity of the Full-Size Series?

A: The particulate filter models deliver flow up to 155 scfm (4,490 l/min) through the standard 5-micron polyethylene element at 100 psig inlet pressure. Coalescing filter variants using borosilicate glass fiber elements provide up to 100 scfm (2,832 l/min) at 100 psig in the standard bowl configuration.

Q: What port sizes does the Full-Size Series cover?

A: The Full-Size Series is available in 1/4-inch, 3/8-inch, 1/2-inch, and 3/4-inch port sizes in both NPT (NPTF) and G (BSPP) thread types. This is the primary series for 3/4-inch port applications before stepping up to the High Capacity Series for higher flows at 3/4 inch and above.

Q: How does the Full-Size Series differ from the MD4 Series at 3/4-inch port?

A: At 3/4-inch port size, the Full-Size Series provides 155 scfm and the MD4 provides 204 scfm. The MD4 also supports diaphragm-type regulator configurations, a wider range of drain options including electronic drain, integrated L-O-X lockout valve options, and clean air packages. The Full-Size Series is the established design; the MD4 is the advanced design for new machine specifications requiring higher flow or expanded options at 3/8 to 3/4 inch.

Q: What bowl options are available?

A: The standard bowl is high-strength polycarbonate with a steel shatterguard (8-oz / 240-ml capacity). The metal bowl option is zinc with a clear nylon sight glass (8-oz capacity). For coalescing filter variants, an extended aluminum bowl (20-oz / 600-ml) is available for applications with high condensate generation or where longer time between drains is needed.

Q: What is the maximum operating temperature?

A: Polycarbonate bowl models are rated to 125 F (52 C). Zinc metal bowl models are rated to 175 F (79 C). Both ratings apply to ambient and media temperatures simultaneously. For process or heated industrial environments above 125 F, the metal bowl must be selected.

Q: What is the maximum inlet pressure?

A: Polycarbonate bowl models are rated to 150 psig (10 bar). Zinc metal bowl models are rated to 200 psig (14 bar). These ratings apply to both automatic drain and manual drain configurations. The steel shatterguard on polycarbonate bowls provides personnel protection if bowl failure occurs near the 150 psig maximum.

Q: Does the steel shatterguard replace the need for a metal bowl?

A: The steel shatterguard on polycarbonate bowls provides personnel protection by containing bowl fragments in the event of bowl failure. It does not change the pressure or temperature rating of the polycarbonate bowl (150 psig, 125 F). If higher pressure (above 150 psig) or temperature (above 125 F) is required, the metal bowl must be selected.

Q: What filtration levels are available?

A: Particulate filter models offer 5-micron polyethylene (standard), 20-micron sintered bronze, and 40-micron sintered bronze elements. Coalescing filter variants use 0.3-micron (standard, 947K77) and 0.01-micron (948K77) borosilicate glass fiber elements. Oil vapor adsorbing filter variants are also available for hydrocarbon vapor removal.

Q: Are BSPP (G) thread models available?

A: Yes. For G (BSPP) threads, add the prefix C to the NPT model number. For example, C5021B5008 is the 3/4-inch G thread, auto drain, polycarbonate bowl Full-Size Series filter.

Q: What replacement element is standard for Full-Size Series particulate filters?

A: The standard 5-micron polyethylene replacement element is 939K77. This element is specific to the Full-Size Series and is physically distinct from the 933K77 (Bantam/Miniature), 936K77 (Mid-Size), or MD3/MD4 elements. Verify the correct element part number when ordering replacements.

Q: Can the Full-Size Series integrate with modular FRL station assemblies?

A: Yes. Modular-mount Full-Size Series filters connect to port kits and manifold hardware to build multi-component FRL stations with a common inlet and outlet. Inline models install directly in a pipeline without manifold hardware. Both configurations are standard catalog items.

Q: Is an internal float drain available on the Full-Size Series?

A: Yes. Internal float drain is available on select Full-Size Series configurations. The float drain provides automatic condensate drainage similar to automatic drain models but uses a different float mechanism. Contact ROSS Controls for internal float drain model number availability.

Installation & Maintenance Guidelines

• Mount with bowl pointing down. Vertical installation is required for automatic drain operation and condensate collection by gravity.
• Install an upstream isolation shutoff valve to enable element replacement and service without full system depressurization.
• Verify the steel shatterguard is properly installed on the polycarbonate bowl before pressurization. The shatterguard must fully encircle the lower bowl section.
• For coalescing filter installation, always install a 5-micron particulate filter upstream. Liquid water carryover into the coalescing element saturates the glass fiber media and degrades oil separation efficiency.
• Replace particulate elements when differential pressure reaches 10 psig (0.7 bar) or at scheduled maintenance intervals. Full-Size elements at 155 scfm service loads may require more frequent replacement than smaller-series elements.
• For metal bowl models in elevated temperature service (above 125 F), verify that upstream supply conditions (oil carryover, moisture) meet the coalescing or particulate filter performance requirements at elevated temperature.
• Do not exceed maximum inlet pressure for bowl type: 150 psig for polycarbonate with steel shatterguard, 200 psig for zinc metal bowl.
• Manual drain models: drain accumulated condensate at regular intervals before liquid level reaches the bottom of the filter element.
• For modular station assembly, verify all port kit seals are properly seated and port kit fasteners are tightened to manufacturer specifications before applying system pressure.
• For G (BSPP) thread installations, use appropriate thread sealant compatible with compressed air service. Do not use PTFE tape on BSPP threads; use a liquid thread sealant.

Warranty & Global Support

ROSS Controls provides a one-year warranty on all Full-Size Series 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 selection assistance, technical support, and distributor locator services.

For complete dimensional drawings, flow curves, and catalog data for the Full-Size Series, visit the ROSS Controls product page at rosscontrols.com or download the ROSS FRL catalog.

Download Catalog: https://www.rosscontrols.com/en/series/70-full-size-series