Piping Flange Kits Connection Piping Kits

Product Overview

The ROSS Controls Piping Flange Kits are connection piping kits designed for use with ROSS Series 35 SERPAR and CrossFlow double valves in Basic Sizes 4, 8, 12, and 30. Each kit provides all the components required to make clean, leak-free flanged port connections between the double valve body and the process piping in a press control or safety circuit installation.

Each piping flange kit includes all required seals and mounting bolts. Kits are available in NPT and BSPP (G) thread configurations, matching the thread type of the double valve. The flange kits cover all port sizes from 3/8 in. through 2 in., with dedicated kit part numbers for each basic valve size and port size combination.

Piping flanges are included as standard equipment on most Series 35 double valves ordered from the current ROSS Controls catalog. Replacement valves for service in existing installations are available as valve-only parts (without flanges). In these cases, the piping flange kits allow the installer to reuse the original flanges from the existing installation or to order new flanges when the original flanges are unavailable or damaged.

The 1999H77 kit enables the 2 in. port option for Basic Size 30 valves. The 2 in. port configuration is not available as a standard assembled valve and requires this flange kit ordered separately from the valve body.

Key Engineering Features

• Complete Kit with All Required Components - Each kit includes all seals and mounting bolts needed to complete the flanged port connection. No additional hardware is required.
• NPT and BSPP Thread Options - All kits are available in NPT (standard catalog number) and BSPP/G thread (D prefix). Specify the thread type matching the valve and system piping.
• Dedicated Kits per Valve Size and Port Size - Separate kit part numbers are provided for each combination of basic valve size and nominal port size, ensuring correct seal dimensions and bolt patterns.
• Enables 2 in. Port Option on Size 30 - The 1999H77 flange kit is the required accessory to configure Basic Size 30 valves for 2 in. port operation. The 2 in. port is not included with the standard valve.
• Supports Valve Replacement without Pipe Disturbance - When replacing a double valve, the piping flanges remain in the piping system. A replacement valve-only (without flanges) is installed between the retained flanges using new seals from the flange kit.
• Compatible with All 35 Series Valve Monitor Types - Flange kits are compatible with SERPAR L-G monitor, SERPAR E-P monitor, SERPAR D-S monitor, and CrossFlow pressure switch valve models of the same basic size and port size.

Technical Specifications

General Specifications

Certifications & Compliance

Typical Applications & Industries

Press Control Valve Installation and Replacement

• New installation of Series 35 SERPAR or CrossFlow double valves in press clutch/brake control circuits, where the valve is supplied without flanges and the installer must provide the flanged port connections.
• Replacement of a failed Series 35 double valve using a valve-only (no flanges) service replacement part. The original flanges remain in the piping system and the new seals from the flange kit restore the flanged connection.
• Upgrade of an existing double valve installation from one port size or basic size to another, where new flange kits for the new configuration are required.

Maintenance and Service

• Scheduled valve service and overhaul on press control circuits where the flanged connections must be disassembled and reassembled with fresh seals.
• Post-accident restoration of press control circuits where flanges may have been damaged and require replacement along with the valve body.

Ordering and Model Number Configuration

Select the piping flange kit by matching the basic valve size (4, 8, 12, or 30) and nominal port size of the Series 35 double valve. Use the D prefix for BSPP/G threads. The 1999H77 kit is required to configure Basic Size 30 for 2 in. port operation and must be ordered separately from the valve body.

Always verify the basic valve size and port size before ordering. The flange geometry, seal dimensions, and bolt pattern differ between basic sizes and between port sizes within the same basic size.

For BSPP (G) thread flanges, add D prefix to the kit model number (e.g., D665K77 for 1 in. port Size 12 with BSPP threads).

The 1999H77 flange kit for 2 in. port on Basic Size 30 is required and must be ordered separately from the valve. The 2 in. port is not available as a standard assembled valve configuration.

When ordering a replacement valve without flanges, order the flange kit separately if new seals and bolts are needed, even if reusing existing flanges. Never reuse old seals from a previous installation.

Estimated ship date for standard quantities of 10 or fewer kits is typically 3 to 4 weeks. Contact ROSS for lead time on larger quantities.

Piping Flange Kit Selection Table

Related Products & Accessories

• SERPAR 35 Series with Pneumatic L-G Monitor, Ports 1/2 to 2 in. - Internally monitored double valves (Basic Sizes 8, 12, 30) using these flange kits for inline installation. https://www.rosscontrols.com/en/series/183-double-valves-with-pneumatic-l-g-monitor-ports-1-2-to-2
• SERPAR 35 Series with Pneumatic L-G Monitor, Ports 3/8 to 3/4 in. - Basic Size 4 L-G monitored double valves using 658K77, 659K77, and 660K77 flange kits. https://www.rosscontrols.com/en/series/184-double-valves-with-pneumatic-l-g-monitor-ports-3-8-to-3-4
• SERPAR 35 Series with Electro-Pneumatic E-P Monitor - E-P monitored double valves (Basic Sizes 8, 12, 30) using these flange kits. https://www.rosscontrols.com/en/series/186-double-valves-with-electro-pneumatic-e-p-monitor
• CrossFlow 35 Series Double Valves with Pressure Switches, 3/8 to 1-1/2 in. - Externally monitored double valves (Basic Sizes 4, 8, 12, 30) using these flange kits for inline installation. https://www.rosscontrols.com/en/series/181-double-valves-with-pressure-switches-ports-3-8-to-1-1-2
• DM2 Series D Double Valves for Clutch/Brake Control - Self-monitored base-mounted double valves for press clutch/brake applications. https://www.rosscontrols.com/en/series/52-double-valves-for-clutch-brake-control

Frequently Asked Questions (FAQ)

Q: What is included in each piping flange kit?

A: Each piping flange kit includes all required seals and mounting bolts necessary to complete the flanged port connections for the specified basic valve size and port size. No additional hardware is needed.

Q: How do I select the correct flange kit?

A: Identify the basic valve size (4, 8, 12, or 30) and the nominal port size (3/8 to 2 in.) of the double valve being installed or replaced. Then select the kit number from the flange kit table that matches both the basic size and port size. For BSPP threads, add the D prefix to the selected kit number.

Q: What is the difference between 665K77 and D665K77?

A: 665K77 is the piping flange kit for Basic Size 12, 1 in. port, with NPT threads. D665K77 is the same kit with BSPP (G) parallel threads. The D prefix denotes BSPP thread type throughout the ROSS Controls product line.

Q: When is the 1999H77 kit required?

A: The 1999H77 flange kit is required when configuring a Basic Size 30 valve for 2 in. port operation. The 2 in. port option is not included with the standard Basic Size 30 valve assembly and must be ordered using this kit number.

Q: Can I reuse the seals from a previous installation?

A: No. Seals from a previous installation should never be reused. Order a new flange kit to obtain fresh seals and bolts whenever the flanged connections are disassembled, whether for valve replacement or routine maintenance.

Q: Are flange kits included with new double valve orders?

A: Most Series 35 double valves ordered from the current ROSS catalog include piping flanges as standard. However, replacement valve-only parts (valve without flanges) are ordered separately. In these cases, a piping flange kit must be ordered if new seals are needed to reinstall the valve.

Q: What is the lead time for piping flange kits?

A: Standard manufacturing lead time for quantities of 10 or fewer units is typically 3 to 4 weeks, with shipping available throughout the United States. Contact ROSS for lead times on larger quantities or international orders.

Q: Do the flange kits work with all Series 35 monitor types?

A: Yes. The same piping flange kits are used for SERPAR 35 Series valves with L-G monitor, E-P monitor, and D-S monitor, and for CrossFlow 35 Series valves with pressure switches. The flange geometry is determined by the basic valve size and port size, not the monitor type.

Q: Are flange kits needed for Basic Sizes 1 and 2 CrossFlow valves?

A: No. Basic Sizes 1 and 2 are base-mounted valves without inline piping flanges. Piping flange kits apply only to Basic Sizes 4, 8, 12, and 30, which are inline-mounted valves with flanged port connections.

Q: What is the correct flange kit for a CrossFlow Basic Size 8 valve with 3/4 in. ports?

A: Use kit 662K77 for NPT threads or D662K77 for BSPP threads. This kit is listed in the flange kit table under Basic Size 8, Nominal Port Size 3/4 in.

Q: Can flange kits be ordered in advance and stocked for maintenance?

A: Yes. Stocking piping flange kits as spare parts reduces press downtime during valve replacement. At a minimum, stock one flange kit for each port size and basic size combination present in the press line. Seals are the consumable components and are included in every kit.

Q: What is the ROSS Controls ordering process for flange kits?

A: Piping flange kits can be ordered directly from ROSS Controls by calling (800) 438-7677, or through authorized ROSS distributors. Reference the kit model number from the flange kit table when placing an order. Provide the thread type (NPT or BSPP) to ensure the correct version is supplied.

Installation & Maintenance Guidelines

• Exhaust all compressed air from the system and apply lockout/tagout per OSHA 29 CFR 1910.147 before disassembling any flanged connections or removing a double valve from service.
• Inspect the flange faces on both the valve body and the process piping connections before installing new flanges. Clean all flange faces to remove scale, corrosion, and old seal material. Do not use old seals from the flange kit.
• Install all seals included in the flange kit in the correct positions as shown in the ROSS 35 Series dimensional drawings. Ensure seals are seated fully in their grooves before torquing bolts.
• Insert all mounting bolts from the flange kit through the flange holes. Hand-tighten all bolts before applying torque. Tighten bolts in a cross pattern to achieve uniform flange compression and prevent seal extrusion.
• Do not overtighten mounting bolts. Excessive torque can crack aluminum valve bodies or cut seals. Follow the torque specifications published in the ROSS 35 Series installation instructions.
• After installation and before returning the press to service, pressurize the valve circuit slowly and check all flanged connections for leaks. Correct any leaks before operating the press.
• For the 1999H77 kit (2 in. port on Basic Size 30), verify that the valve model supports the 2 in. port option. Not all Basic Size 30 models are configured for 2 in. port without the flange kit. Consult the ROSS 35 Series catalog to confirm valve body compatibility.
• Use only the seals supplied in the flange kit for the specified valve size and port size. Seals from different kits are not interchangeable between port sizes or basic sizes.
• When replacing an existing double valve, retain the original piping flanges in place in the piping system. Remove the valve body by unbolting from the flanges. Install the replacement valve-only body between the retained flanges using the new seals from the flange kit.
• Label each flange kit in inventory with the basic valve size, port size, and thread type. Incorrect kit selection is the most common installation error in field service.
• Verify that the thread type of the flange kit (NPT or BSPP) matches the thread type of both the valve and the process piping. NPT and BSPP threads are not interchangeable and using the wrong type will result in leaks.
• Contact ROSS Controls technical support at (800) 438-7677 if the correct flange kit number for a specific valve configuration is not listed in the standard catalog table.

Warranty & Global Support

ROSS Controls provides a one-year warranty on all piping flange kit products, covering defects in material and workmanship from the date of purchase.

Global technical support is available through ROSS offices in the USA (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 identification, ordering assistance, and technical support.

For complete dimensional drawings and installation instructions for Series 35 double valve flange connections, visit rosscontrols.com or contact ROSS Controls at (800) 438-7677.