High Capacity Series Port Sizes 3/4" to 2"; Flow to 1000 scfm (28320 l/min)

Product Overview

The ROSS Controls High Capacity Series is a family of heavy-duty inline air preparation filters engineered for port sizes 3/4 inch through 2 inches (NPT or G/BSPP) with flow capacity up to 1,000 scfm (28,320 l/min). The High Capacity Series is designed for main compressed air supply header filtration, plant air distribution systems, and industrial processes where the flow demands of large pneumatic systems exceed the capacity of the Full-Size, MD3, or MD4 series filters.

The High Capacity Series is available in three flow tiers: the standard high-capacity filter (to 275 scfm at 3/4 and 1-inch ports), the mid-range high-capacity filter (to 660 scfm at 1-1/4 and 1-1/2-inch ports), and the maximum-flow variant (to 1,000 scfm at 1-1/4, 1-1/2, and 2-inch ports). Coalescing filter variants using borosilicate glass fiber elements cover flow rates from 220 scfm through 840 scfm across the port size range.

All High Capacity Series units use aluminum body construction for weight efficiency at large body sizes. Bowl options include high-strength polycarbonate with steel shatterguard (16-oz / 480-ml at 3/4 and 1-inch; 35-oz and 123-oz capacities at larger sizes) and aluminum metal bowl with clear nylon sight glass, extending temperature rating to 175 F (79 C). Drain options include manual drain, automatic drain, and internal float drain across the range.

For plant engineers specifying main air header filtration in manufacturing facilities, process plants, or compressed air distribution systems where flow requirements reach or exceed 200 scfm, the High Capacity Series provides ROSS Controls' highest-flow catalog-standard filter solution with well-characterized replacement elements and accessories.

Key Engineering Features

• Highest Flow Capacity in ROSS FRL Filter Range - Provides flow to 1,000 scfm (28,320 l/min) at 2-inch port size, covering main compressed air supply headers in manufacturing plants, process facilities, and industrial utilities where no other ROSS filter series meets the flow requirement.
• Inline Mounting for Large Port Sizes - All High Capacity Series units are inline-mount, installing directly in the main compressed air supply pipeline at 3/4-inch through 2-inch port sizes.
• Three Flow Tiers to Match Installation Requirements - Standard tier provides up to 275 scfm at 3/4 and 1-inch ports. Mid-range tier provides up to 660 scfm at 1-1/4 and 1-1/2-inch ports. Maximum-flow tier provides up to 1,000 scfm at 1-1/4, 1-1/2, and 2-inch ports. Select the tier matching the required flow and port size.
• Aluminum Body Construction - All High Capacity Series bodies are aluminum, providing an excellent strength-to-weight ratio at large filter body sizes where cast zinc would be prohibitively heavy. Aluminum body also provides corrosion resistance in humid or outdoor installations.
• 5- and 40-Micron Particulate Filtration - Standard 5-micron polyethylene element removes fine particulates and condensate. 40-micron sintered bronze element available for higher-flow coarser-cut prefiltration ahead of 5-micron stages or coalescing filters.
• High-Efficiency Coalescing Filters (0.3 and 0.01 Micron) - Coalescing filter variants using borosilicate glass fiber elements are available across the 3/4-to-2-inch port range, providing ISO 8573-1 Class 1 and Class 2 oil removal at high-flow rates in standard and extended bowl configurations.
• Large Bowl Capacities - Bowl capacities of 16 oz (480 ml) at 3/4 and 1-inch, 35 oz (1,000 ml) at mid-range, and up to 123 oz (3,700 ml) at maximum-flow variants provide extended intervals between drain cycles proportional to the high condensate volumes expected at large header sizes.
• High-Strength Polycarbonate with Steel Shatterguard - Polycarbonate bowl includes steel shatterguard for personnel protection. Metal aluminum bowl with nylon sight glass extends upper operating temperature to 175 F (79 C).
• Internal Float Drain, Automatic Drain, and Manual Drain Options - Three drain mechanism options accommodate diverse installation requirements and condensate accumulation rates at high-flow header installations.
• Dual-Face Differential Gauge - Large dual-face differential pressure gauge included on coalescing filter variants for clear element condition indication at the large unit sizes, visible from typical service aisle distances.

Technical Specifications

General Specifications

Temperature Ratings

All High Capacity Series units use aluminum body construction. Temperature rating depends on bowl material selection.

Important: Do not use polycarbonate bowls at temperatures above 125 F or where chemical exposure to solvents or cleaners may occur. Select the aluminum bowl option for elevated temperature service.

Flow Performance Data

Flow performance at 100 psig inlet pressure, new element. Coalescing filter flows are for selected bowl configurations. Contact ROSS Controls for complete flow curves across all port sizes.

Certifications & Compliance

Typical Applications & Industries

Manufacturing Plant Main Air Supply Headers

• Main plant compressed air supply header filtration at 1-inch to 2-inch pipe headers serving entire manufacturing facilities, where 1,000 scfm capacity accommodates simultaneous demand from all downstream pneumatic users without measurable pressure drop.
• Zone air preparation stations at 1-inch or 1-1/4-inch supply drops from main plant headers, filtering and protecting all downstream equipment in a production zone from compressor-generated particulate and oil carryover.
• Compressed air dryer bypass and main filtration on reciprocating compressor systems where 5-micron elements protect downstream equipment from oil and particulate in facilities without refrigerated dryers.
• Booster compressor outlet filtration where 2-inch port filters serve as the primary particulate barrier between high-pressure booster stages and lower-pressure distribution systems.

Process Industries and Energy

• Instrument air main header filtration in petrochemical plants, refineries, and gas processing facilities where 1-inch to 1-1/2-inch instrument air headers supply hundreds of pneumatic instruments and control valve positioners.
• Compressed air supply filtration for large pneumatic actuators on main process control valves, gate valves, and pipeline isolation valves where 1-inch and larger port sizes match valve actuator supply requirements.
• Plant air supply filtration in power generation facilities including gas turbine compressor air supply conditioning and steam plant pneumatic instrument air systems at high-flow headers.
• Coalescing filter installation (0.01-micron) at main instrument air headers in oil refineries and chemical plants where compressor lube oil carryover at 3/4-inch to 1-1/2-inch supply mains threatens downstream instrument reliability.

Heavy Industry and Metal Processing

• Steel mill compressed air supply filtration for continuous casting, rolling mill, and heat treat line pneumatics at 1-inch to 2-inch main header sizes handling the high air demand of large actuators and pneumatic drives.
• Aluminum and nonferrous smelting and casting operations where main pneumatic supply headers at 1-1/2 to 2 inches require robust filtration to protect casting machine actuators and material handling pneumatics.
• Mining and mineral processing pneumatic supply filtration for drill rigs, conveyor pneumatics, and process control actuators in high-particulate environments where 5-micron filtration is critical to equipment longevity.
• Foundry and forge shop compressed air supply filtration where large-bore pneumatic actuators for die handling, part ejection, and press operations demand clean air at 3/4-inch to 1-1/2-inch supply connections.

Automotive, Aerospace, and Large-Scale Manufacturing

• Stamping press main air supply filtration where 1-inch or larger supply headers serve large pneumatic cushion cylinders, die clamp actuators, and transfer bar systems requiring 275+ scfm at consistent quality.
• Aircraft manufacturing pneumatic supply headers for large assembly jigs, riveting tools, and structural bonding fixture actuators at 1-inch to 1-1/2-inch supply port sizes.
• Shipbuilding and heavy fabrication shop compressed air supply filtration for plasma cutting, grinding, and large pneumatic tooling at facility-level supply headers up to 2 inches.
• Aerospace testing facility compressed air supply at 1-inch to 2-inch supply mains serving high-flow actuator test stands, environmental chambers, and engine test cell pneumatics.

Ordering and Model Number Configuration

The ROSS High Capacity Series uses a structured model number system. Inline units at 3/4 and 1-inch ports use the 5021B/5022B model number format. Larger-bore units (1-1/4 through 2 inch) use the 5022B7xxx series. Coalescing variants use 5031B/5X00B series. Consult the ROSS FRL catalog for complete model number details.

High Capacity Series consists of three distinct flow tiers (275, 660, 1,000 scfm) with different body sizes and model number series. Specify the correct tier for the required port size and flow.

Sintered bronze elements are standard on mid-range and maximum tier units (5-micron and 40-micron options). Polyethylene elements are standard on the 3/4 and 1-inch standard tier.

Coalescing filter variants have separate model number series (5031B and 5X00B); consult the ROSS FRL catalog for full coalescing model selection.

Internal float drain is available at all tiers. Verify minimum 30 psig inlet supply for float drain operation.

For G (BSPP) threads, contact ROSS Controls for applicable model numbers.

Accessories

Replacement Filter Elements

ROSS replacement elements for High Capacity Series. Element part numbers vary by tier and filtration level. Confirm correct element for specific model before ordering.

Dual-Face Differential Pressure Gauge

Large dual-face differential pressure gauge is included with High Capacity Series coalescing filter variants. The gauge monitors pressure drop across the coalescing element and alerts when replacement is required. The dual-face design allows gauge reading from two aisle directions, important given the large unit dimensions.

Related Products & Accessories

• Full-Size Series Air Preparation Filters - Modular and inline filters for 1/4 to 3/4 port sizes with flow to 155 scfm, for installations below High Capacity range. https://www.rosscontrols.com/en/series/70-full-size-series
• MD4 Series Air Preparation Filters - Advanced modular filters 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
• MD3 Series Air Preparation Filters - Modular filters for 1/4 to 1/2 port sizes with flow to 92 scfm and L-O-X lockout valve integration. https://www.rosscontrols.com/en/series/72-md3-series
• L-O-X Lockout Valves - OSHA-compliant pneumatic lockout valves for energy isolation at main air supply lines and sub-header shutoffs. https://www.rosscontrols.com/en/series/1287-lockout-valves-15-series

Frequently Asked Questions (FAQ)

Q: What flow capacities does the High Capacity Series cover?

A: The High Capacity Series covers three flow tiers: 275 scfm (7,789 l/min) for 3/4 and 1-inch port units; 660 scfm (18,688 l/min) for 1-1/4 and 1-1/2-inch units; and 1,000 scfm (28,320 l/min) for 1-1/4, 1-1/2, and 2-inch maximum-flow units. Coalescing filter variants span 220 to 840 scfm depending on port size and bowl configuration.

Q: What port sizes does the High Capacity Series support?

A: The High Capacity Series is available in 3/4-inch, 1-inch, 1-1/4-inch, 1-1/2-inch, and 2-inch port sizes. The standard tier covers 3/4 and 1 inch; the mid-range tier covers 1-1/4 and 1-1/2 inch; the maximum-flow tier extends to 2 inches.

Q: What filtration levels are available?

A: The standard tier (3/4, 1 inch) uses 5-micron polyethylene elements. The mid-range and maximum tiers use 5-micron and 40-micron sintered bronze elements. Coalescing filter variants use 0.3-micron and 0.01-micron borosilicate glass fiber elements across all port sizes.

Q: What is the maximum operating pressure?

A: Polycarbonate bowl models are rated to 150 psig (10 bar). Aluminum metal bowl models are rated to 200 psig (14 bar). Internal float drain models require minimum 30 psig. All High Capacity Series units use aluminum body construction.

Q: What is the maximum operating temperature?

A: Polycarbonate bowl models are rated from 40 to 125 F (4 to 52 C). Aluminum bowl models are rated from 40 to 175 F (4 to 79 C). For high-temperature compressor room installations or outdoor headers in warm climates, the aluminum bowl is recommended.

Q: Why does the High Capacity Series use aluminum bodies?

A: At large filter body sizes (1-inch through 2-inch ports), cast zinc or acetal body construction would result in excessive unit weight. Aluminum provides the required structural strength and pressure-retaining integrity at significantly lower weight. Aluminum also offers corrosion resistance for outdoor or humid installation environments.

Q: What bowl capacities are available?

A: Bowl capacity scales with unit size: 16 oz (480 ml) for the 3/4 and 1-inch standard tier; 35 oz (1,000 ml) for mid-range units; 123 oz (3,700 ml) for maximum-flow 2-inch units. Large bowl capacities are necessary at high flow rates where condensate accumulation rates are proportionally greater, maintaining acceptable intervals between drain cycles.

Q: What drain options are available?

A: Automatic drain, manual drain, and internal float drain options are available across the High Capacity Series range. The internal float drain requires a minimum 30 psig inlet pressure. For very large units (1-1/2 and 2 inch) where automatic drain capacity may be insufficient for the condensate volumes generated, consult ROSS Controls regarding external automatic drain options.

Q: Is the High Capacity Series inline-only or can it be used in modular assemblies?

A: The High Capacity Series is inline-only. At port sizes of 3/4 inch and above, the physical size and flow requirements of the units make modular manifold assembly impractical. Individual inline units are installed in the main supply pipeline and flanked by isolation valves for maintenance access.

Q: What is the replacement element for standard-tier units?

A: The standard 5-micron polyethylene replacement element for 3/4 and 1-inch standard tier units is 1010K77. Mid-range sintered bronze elements are 1656K77 (5 micron) and R-A114-106E3 or 944K77 (40 micron). Always verify the element part number against the specific model being serviced before ordering replacements.

Q: Can the High Capacity Series coalescing filter be installed without a preceding particulate filter?

A: No. A 5-micron particulate prefilter must always be installed upstream of coalescing filter stages. Liquid water entering the coalescing element saturates the borosilicate glass fiber media and destroys its oil-coalescing capability. The coalescing filter is designed to remove oil aerosols from air that has already been freed of bulk liquid by the upstream particulate filter.

Q: Are the High Capacity Series units suitable for outdoor installation?

A: High Capacity Series aluminum body units are suitable for outdoor installations with appropriate weatherproofing. The aluminum body provides corrosion resistance, and the metal bowl option is recommended for outdoor temperature cycling that may exceed polycarbonate bowl temperature limits in warm climates. Freeze protection must be provided below 40 F (4 C) to prevent condensate freezing in the bowl and drain mechanism.

Installation & Maintenance Guidelines

• Install inline with flow direction matching unit markings. For large-bore units (1-1/2 and 2 inch), use proper pipe support and alignment to prevent mechanical stress on body ports from piping weight and thermal expansion.
• Mount with bowl pointing down. Vertical installation is required for automatic and float drain function and for condensate collection by gravity.
• Install isolation shutoff valves both upstream and downstream of the filter to enable element replacement without draining or depressurizing the entire header system.
• Always install a 5-micron particulate filter upstream of any coalescing filter stage. Liquid water carryover into the coalescing element destroys the glass fiber media.
• For float drain models, verify minimum 30 psig inlet supply pressure is maintained during all operating conditions. Startup pressure below 30 psig will cause the float to remain open.
• Replace particulate elements when differential pressure reaches 10 psig (0.7 bar) or at scheduled maintenance intervals. At 275 to 1,000 scfm service flows, element loading rates are proportionally high; more frequent inspections are recommended.
• For coalescing filter models, use the included dual-face differential gauge to monitor element condition. Replace coalescing elements when the gauge indicates the replacement threshold pressure drop.
• At 1-1/2 and 2-inch port sizes, use appropriate pipe wrenches and pipe fitting installation practices. Do not apply excessive torque that could deform the aluminum body ports.
• In cold environments (below 40 F), provide heat tracing or insulated enclosures to prevent condensate freezing in the bowl and drain mechanism.
• For outdoor installations, protect the unit from direct rainfall and UV exposure with appropriate enclosures or shielding. UV exposure degrades polycarbonate bowls over time; use aluminum bowls for long-term outdoor service.

Warranty & Global Support

ROSS Controls provides a one-year warranty on all High Capacity 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 ordering details for all High Capacity Series tiers, visit the ROSS Controls product page at rosscontrols.com or download the ROSS FRL catalog.

Download Catalog: https://www.rosscontrols.com/en/series/71-high-capacity-series