High Capacity Series Port Sizes 1-1/4 to 2; Flow to 1000 scfm (28320 l/min)

Product Overview

The ROSS Controls High-Capacity Coalescing Filter delivers industrial-scale aerosol removal for the largest compressed air systems, covering port sizes from 1-1/4 to 2 inches with maximum flow to 1000 scfm (28320 l/min). Designed for inline mounting in main compressed air distribution headers, large process equipment air preparation stations, and high-flow FRL applications, the series provides effective 0.3-micron or 0.01-micron filtration at flow rates that far exceed the capacity of any mid-size or modular coalescing filter series.

The coalescing mechanism in the series captures liquid water droplets, aerosol oil, and sub-micron particulate contamination generated by oil-lubricated compressors, aftercoolers, and air receivers before the compressed air reaches distribution piping, process equipment, and pneumatic systems downstream. At high flow rates, effective coalescing filtration at the system inlet prevents contamination propagation throughout the entire facility air distribution network, eliminating the need for individual point-of-use coalescing filtration at each machine.

Bowl options address a range of installation environments. The high-strength polycarbonate plastic bowl with a steel shatterguard provides visual condensate-level inspection and impact protection at pressures to 150 psig (10 bar). The aluminum bowl with clear nylon sight glass extends the pressure rating to 200 psig (14 bar) and temperature to 175 degrees F (80 degrees C). An extended aluminum bowl configuration increases liquid storage capacity for applications with high condensate generation rates. Automatic and manual drain options accommodate different condensate management requirements and system pressure profiles.

An integral differential pressure gauge on all Series coalescing filter models enables element condition monitoring for condition-based maintenance scheduling. For facilities with predictive maintenance programs, this gauge provides the quantitative element loading data needed to optimize replacement intervals based on actual system contamination levels rather than arbitrary time schedules.

Key Engineering Features

• Flow to 1000 scfm (28320 l/min) - Maximum flow capacity of any ROSS coalescing filter series, supporting main compressed air supply headers, large compressor room discharge filtration, and high-flow industrial plant air preparation.
• Port Sizes 1-1/4 to 2 Inches - Covers the full range of large-bore industrial compressed air distribution pipe sizes from 1-1/4 to 2 inches, enabling direct in-line installation in main distribution headers without reducing adapters.
• 0.3-Micron and 0.01-Micron Element Options - Borosilicate glass-fiber coalescing elements in 0.3-micron for general industrial aerosol removal and 0.01-micron for near oil-free air quality, available across all port sizes and bowl configurations.
• High-Strength Polycarbonate Bowl with Steel Shatterguard - Visual inspection capability at operating pressures up to 150 psig (10 bar) with the safety of an integral steel shatterguard that retains bowl fragments in impact or overpressure events.
• Aluminum Bowl with Clear Nylon Sight Glass - Metal bowl option for pressures to 200 psig (14 bar) and temperatures to 175 degrees F (80 degrees C) with a clear nylon sight glass for condensate level inspection.
• Extended Aluminum Bowl Option - Extended bowl increases liquid storage capacity beyond the standard bowl for high-condensate-generating main air systems, reducing drain frequency and simplifying condensate management.
• Differential Pressure Gauge - Standard on all Series models, providing direct element loading status to maintenance personnel and enabling condition-based element replacement scheduling at large-scale facilities.
• Automatic or Manual Drain - Automatic drain removes collected liquid continuously without operator intervention; manual drain provides direct operator control, both options available across all port sizes in the series.
• Inline Mounting for Main Distribution - Inline pipe-threaded mounting design installs directly in the main compressed air supply line, providing system-level filtration for the entire facility downstream of the installation point.

Technical Specifications

General Specifications

Certifications & Compliance

Typical Applications & Industries

Main Compressed Air Supply and Distribution

• Compressor room outlet filtration installed directly on the main compressed air header downstream of aftercoolers and moisture separators, where system-level coalescing filtration protects the entire facility distribution network from oil carryover.
• Large plant compressed air main distribution filtration at the supply header entry point to manufacturing areas, eliminating the need for individual point-of-use coalescing filters throughout the facility by delivering clean air at the distribution source.
• Compressed air receiver outlet filtration where accumulated water and oil in the receiver can be entrained in the air flow during high-demand periods, and a high-capacity coalescing filter at the receiver outlet intercepts these slugs before they enter the distribution system.

Large-Scale Manufacturing Plants

• Automotive assembly plant air preparation for compressed air systems serving body shop, paint shop, and final assembly areas, where the 2-inch port size and 840 scfm capacity matches the main distribution header requirements in large-volume production facilities.
• Steel and metal processing facility air preparation where the main compressed air system supplies pneumatic controls, actuators, and air tools across a large facility footprint, and central coalescing filtration at the inlet controls contamination for all downstream equipment.
• Chemical and petrochemical plant instrument air system coalescing filtration on the main 1-1/2 or 2-inch instrument air header, ensuring the air quality delivered to pressure transmitters, positioners, and control valves meets instrument air specifications across the entire plant.

Power Generation and Utilities

• Power plant instrument air filtration for turbine control systems, boiler controls, and pneumatic safety instruments where a high-capacity coalescing filter at the main instrument air supply provides system-wide protection for critical control equipment.
• Natural gas compressor station instrument air preparation where the 200 psig metal bowl rating covers the elevated system pressures common in high-pressure natural gas facility utilities, and the high flow capacity serves multiple instrument panels from a single unit.

Food and Beverage Processing Facilities

• Brewery, dairy, and food processing plant main air header coalescing filtration providing facility-wide oil-free air from a single high-capacity unit, replacing multiple smaller coalescing filters at individual machine drops with a centralized high-capacity solution.
• Large-scale beverage bottling and canning line air preparation where the 1-1/2 or 2-inch port size of the series matches the main compressed air supply connections typical in high-throughput production facilities.

Mining, Aggregate, and Heavy Industry

• Mining and aggregate processing facility compressed air preparation for pneumatic control systems, rock drills, and material handling equipment where the main compressed air system is served by large reciprocating compressors with significant oil carryover.
• Shipyard and offshore platform compressed air system coalescing filtration where high humidity environments generate large condensate volumes and 2-inch port main headers serve extended distribution systems.

Ordering and Model Number Configuration

Model number prefix varies by port size group. Representative examples: 5X00B5099 for 3/4 auto drain polycarbonate; 5031B5008 for similar inline configuration.

For 1-1/4 and 1-1/2 port sizes, flow capacity is 465 scfm with standard bowl or higher with extended bowl configurations.

For 2-inch port size, the extended bowl is required; flow to 840 scfm.

Drain options: automatic, manual, and internal float drain available. Float drain requires minimum 30 psig (2 bar) inlet pressure.

Extended bowl models are designated by an extended bowl suffix in the model number. Consult ROSS Controls for the complete model number structure for each port size and bowl type combination.

For BSPP (G) thread ports, consult ROSS Controls for applicable model number prefix.

Accessories including external automatic drain kits, mounting hardware, and element replacement kits are ordered separately.

Related Products & Accessories

• MD4 Series Coalescing Filter - High-flow coalescing filter for 3/8 to 3/4 port sizes at flows to 158 scfm, the next smaller series below the High-Capacity. https://www.rosscontrols.com/en/series/83-md4-series
• High-Capacity Series Standard Filters - 5-micron general-purpose particulate filters in the High-Capacity size range for upstream pre-filtration ahead of the coalescing stage. https://www.rosscontrols.com/en/categories/40-filters
• Coalescing Filter Element 952K77 - 0.3-micron borosilicate glass-fiber replacement element for the High-Capacity Series 1-1/4 and 1-1/2 port standard bowl configuration. https://www.rosscontrols.com/en/series_variants/512524-952k77
• Coalescing Filter Element 949K77 - 0.3-micron replacement element for the High-Capacity Series 3/4-port standard bowl configuration. https://www.rosscontrols.com/en/series_variants/512517-945k77
• High-Capacity Series Regulators - Large-bore precision pressure regulators for 1-1/4 to 2 port sizes compatible with the series installation requirements. https://www.rosscontrols.com/en/categories/42-regulators

Frequently Asked Questions (FAQ)

Q: What is the maximum flow rating of the High-Capacity Series?

A: The Series is rated for flow to 1000 scfm (28320 l/min). The flow capacity varies by port size: 220 scfm for 3/4-port configurations, 295 to 450 scfm for 1-inch configurations, 465 scfm for 1-1/4 and 1-1/2 port configurations, and 840 scfm for the 2-inch port extended bowl configuration. The total product family range is cataloged as covering flows to 840 scfm in the standard ROSS product line; higher-flow configurations are available on request.

Q: What port sizes are available in the High-Capacity Series?

A: The Series covers port sizes from 3/4 inch through 2 inches, including 3/4", 1", 1-1/4", 1-1/2", and 2" NPT (standard) with BSPP available. The port size selection determines the appropriate element model number.

Q: Is the series designed for inline or modular mounting?

A: The High-Capacity Series is designed exclusively for inline mounting. At the large pipe sizes served by this series, modular assembly with adjacent regulators and lubricators is not practical. For high-flow FRL requirements, the series coalescing filter is installed inline and can be followed by appropriately sized high-capacity regulators and lubricators in the compressed air line.

Q: What is the maximum operating pressure?

A: Maximum operating pressure is 200 psig (14 bar) for both automatic and manual drain configurations with aluminum bowl. Float drain configurations require a minimum of 30 psig (2 bar) at the filter inlet for activation. The 200 psig rating covers all standard industrial compressed air systems and the majority of instrument air systems.

Q: What is the temperature rating of the series?

A: Operating temperature range is 40 to 175 degrees F (4 to 80 degrees C) for ambient and media temperature. The aluminum body and bowl construction provides consistent performance across this full range.

Q: How do I select the correct replacement element for my configuration?

A: The correct element model depends on the port size, bowl type (standard or extended), and element rating (0.3 or 0.01 micron). For 3/4-port standard bowl: 949K77 (0.3 micron) or R-A109-106E8 (0.01 micron). For 1-inch standard bowl: R-A114-112 or R-A114-112E8. For 1-1/4 and 1-1/2 inch standard bowl: 952K77 (0.3 micron) or R-A106-24E8 (0.01 micron). For extended bowls (1-1/4, 1-1/2, 2 inch): 953K77 (0.3 micron) or R-A106-24LE8 (0.01 micron). Consult ROSS Controls with the complete model number for confirmation.

Q: Is an external automatic drain available for the High-Capacity Series?

A: Yes, an external automatic drain option is available for the High-Capacity Series. This option is particularly useful in large-diameter filter installations where condensate volumes are significant and continuous automatic purging is required without the size constraints of an internal float mechanism.

Q: Can the series filter be used in high-humidity outdoor installations?

A: Yes. The aluminum body and bowl construction of the series is suitable for outdoor installation within the rated temperature range. For outdoor installations, ensure the automatic drain outlet is directed away from walkways and equipment, and that freeze protection (adequate air drying or heat tracing) is provided for cold-climate locations.

Q: How does central high-capacity coalescing filtration compare to distributed point-of-use filtration?

A: A single high-capacity coalescing filter at the main compressed air header inlet protects all downstream equipment from a single maintenance point. This approach reduces installation cost and maintenance labor compared to individual coalescing filters at each machine drop, but requires the main header filter to be correctly sized for the peak facility air demand. If contamination levels vary significantly between areas of a facility, or if some machines require oil-free air while others do not, a combination of main header coalescing and point-of-use filtration at sensitive machines may be the most cost-effective approach.

Q: What happens if the automatic drain fails or is not functioning?

A: If the automatic drain fails to open, condensate accumulates in the bowl. When the bowl reaches capacity, liquid begins to be entrained in the air flow past the element, causing liquid carryover into the downstream system. Monitor the bowl sight glass or condensate level indicator at regular intervals when using the automatic drain. If the drain is suspected of not operating, perform a manual purge test and inspect the drain mechanism. Replace the drain assembly if it fails to actuate under rated pressure.

Q: What is the bowl sight glass material?

A: The aluminum bowl option includes a clear nylon sight glass that provides visual inspection of the condensate level without removing the bowl. The nylon sight glass is resistant to compressed air and petroleum-based compressor oil condensate across the rated temperature range.

Q: What is the lead time for High-Capacity Series coalescing filters?

A: Standard manufacturing lead times for quantities of 10 or fewer units are typically 3 to 4 weeks. For larger quantities or special configurations (non-standard port sizes, non-standard drain types), contact ROSS Controls at (800) 438-7677 for specific lead time and availability information.

Installation & Maintenance Guidelines

• Install inline with the bowl pointing downward. At the large flow rates and port sizes served by the series, proper drainage orientation is critical to prevent liquid accumulation in the element and downstream liquid carryover.
• Provide upstream particulate filtration (5-micron or 40-micron) before the coalescing filter, particularly in main header applications where pipe scale, welding debris, and rust from older distribution piping can rapidly load the coalescing element.
• For float drain models, ensure minimum inlet pressure of 30 psig (2 bar) is maintained continuously to activate the float mechanism. Main air header pressure is typically adequate, but verify during low-demand periods.
• For large-bore (1-1/2 and 2-inch) installations, use pipe supports and appropriate flanged or threaded adapters at both inlet and outlet to ensure the filter body is not subject to pipe strain loads from the weight of the connecting piping.
• Monitor the differential pressure gauge weekly during initial operation to understand the contamination loading rate for the specific compressor and system. Establish the element replacement interval based on observed differential pressure rise rate.
• For high condensate-generating systems or in facilities without continuous maintenance coverage, specify the automatic drain option. Verify drain outlet piping is free-draining and terminates in an appropriate condensate collection or disposal point.
• Depressurize and isolate the high-capacity filter completely before performing element replacement. At large port sizes, stored system energy is substantial; use appropriate lockout-tagout procedures before opening the filter.
• Confirm adequate floor-level clearance for bowl removal during element replacement. The extended bowl configurations of the series have significant hanging length below the body; verify maintenance access before installation.

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

Contact ROSS Controls USA at (800) 438-7677 (1-800-GET-ROSS) or visit rosscontrols.com for product configuration, technical support, and distributor locator services.

Technical service is available at 1-888-TEK-ROSS for application engineering support and replacement parts identification.

Download Catalog: https://www.rosscontrols.com/en/series/84-high-capacity-series