Full-Size Series Port Sizes 1/4 to 1/2; Flow to 100 scfm (2832 l/min)

Product Overview

The ROSS Controls Full-Size Coalescing Filter provides robust aerosol removal for 1/4 to 1/2 port pneumatic systems at flow rates to 100 scfm (2832 l/min). Available with a 0.3-micron standard coalescing element or an optional 0.01-micron ultra-fine element, the Full-Size Series removes liquid water and aerosol oil from compressed air lines, protecting downstream pneumatic valves, cylinders, instruments, and process equipment from contamination-related failures.

The Series offers a choice of three bowl configurations matched to different environmental and pressure requirements. The high-strength polycarbonate plastic bowl with a steel shatterguard provides both visual liquid-level inspection and impact protection at operating pressures up to 150 psig (10 bar). The zinc bowl with clear nylon sight glass provides a higher-pressure metal bowl option with the convenience of a sight glass. An extended bowl version of the metal configuration adds liquid storage capacity for high-condensate environments.

Both modular and inline mounting configurations are supported. In modular installations, the series connects directly to Full-Size Series regulators and lubricators through ROSS porting block assemblies, eliminating intermediate pipe fittings and creating a compact integrated FRL station. The zinc body construction provides the structural rigidity required for reliable modular port block connections across repeated pressurization cycles.

The differential pressure gauge standard on all Series coalescing filter models allows maintenance personnel to assess element loading by direct visual inspection at the filter, enabling condition-based element replacement scheduling rather than fixed time intervals. Automatic and manual drain configurations are available to match the condensate management requirements of each installation.

Key Engineering Features

• 0.3-Micron Coalescing Element with 0.01-Micron Option - Standard 0.3-micron borosilicate glass-fiber element removes bulk aerosol oil and liquid water. Optional 0.01-micron element achieves near oil-free air quality for instrumentation, pharmaceutical, and food-grade applications.
• Steel Shatterguard on Polycarbonate Bowl - The polycarbonate bowl option includes an integral steel shatterguard that retains bowl fragments in the event of an impact or overpressure event, providing a level of safety protection beyond standard clear bowls.
• Three Bowl Configuration Options - High-strength polycarbonate with steel shatterguard (standard, up to 150 psig); zinc bowl with clear nylon sight glass (metal, up to 200 psig); and extended metal bowl for increased liquid storage capacity.
• Differential Pressure Gauge - Integral differential pressure gauge on all Full-Size Series coalescing filter models provides direct, real-time element condition monitoring for condition-based maintenance scheduling.
• Modular or Inline Mounting - Supports both modular assembly with Full-Size Series regulators and lubricators via porting block kits and direct inline pipe-threaded installation, matching the installation topology of the pneumatic system.
• Zinc Body Construction - Die-cast zinc body provides superior thread integrity and modular port block sealing surface quality, ensuring reliable pipe connections and leak-free modular joint interfaces across the rated pressure range.
• Port Sizes 1/4 to 1/2 - Covers the full range of mid-to-large industrial pneumatic pipe sizes, from the 1/4" connections common on individual machine circuits to the 1/2" connections used on main branch air drops feeding multiple machines.
• Automatic or Manual Drain - Automatic drain provides continuous hands-free condensate removal; manual drain gives the operator direct control and is preferable for systems where automatic drain activation would disturb downstream pressure-sensitive processes.
• Nitrile Seals for Industrial Compressed Air - Standard Nitrile seals provide reliable sealing performance with compressed air and petroleum-based compressor oils throughout the rated temperature and pressure envelope.

Technical Specifications

General Specifications

Certifications & Compliance

Typical Applications & Industries

Industrial Automation and Manufacturing

• Machine tool and CNC machining center air preparation where contaminated compressed air leads to valve stiction, cylinder seal failures, and oil contamination of workpieces and cutting tools.
• Robotic cell and servo-pneumatic system air preparation where consistent, clean air quality is required for repeatable actuator performance and to protect proportional valve internals from particulate and oil degradation.
• Modular FRL assemblies for automated assembly lines where the Full-Size Series integrates with Full-Size regulators and lubricators in a compact assembly that fits within a standard machine panel enclosure.

Automotive and Transportation

• Compressed air preparation in automotive body shop weld cells, transfer press pneumatic circuits, and stamping line pneumatic systems where high contamination levels from aging compressor infrastructure demand robust coalescing filtration.
• Air preparation for tire and wheel assembly test equipment, air-driven tooling, and leak test stands where oil-free, dry air is required for consistent test results and to prevent tool contamination.

Packaging and Processing

• Air preparation on form-fill-seal packaging machines, labeling systems, and bottle-handling conveyors where the 1/4 to 1/2 port size covers the standard machine air supply connection and the 100 scfm rating accommodates aggregate actuator demand.
• Compressed air supply to air knives, blow-off systems, and pneumatic drying stations on paper, film, and web-handling machines where oil-contaminated air would deposit residue on product surfaces.
• Process equipment air preparation in chemical and materials processing plants where the metal bowl option provides the pressure and temperature performance required for demanding industrial environments.

Semiconductor and Electronics

• Clean-room air preparation for semiconductor handling, wafer inspection, and PCB assembly where the 0.01-micron element removes trace aerosols before air reaches contamination-sensitive process equipment.
• Air bearing and air spindle supplies for precision measurement and positioning equipment where any oil in the air supply would contaminate the bearing surface and degrade rotational accuracy.

Food and Beverage

• Food processing machine air preparation for filling, capping, and conveying systems where the 0.01-micron element removes aerosol oil ahead of product contact zones.
• Beverage dispensing and carbonation system air preparation where compressed air contacts product or packaging and must meet food-grade air purity requirements.

Ordering and Model Number Configuration

Bowl options: high-strength polycarbonate with steel shatterguard (standard); zinc bowl with clear nylon sight glass (standard or extended). Specify bowl type at time of order.

Element rating: 0.3 micron (standard on base model); 0.01 micron available as an upgrade. Verify element model number matches the bowl type selected.

Accessories including porting blocks, coupling kits, mounting brackets, and external automatic drain kits are ordered separately.

For BSPP (G) thread ports, consult ROSS Controls for the model number prefix convention applicable to Full-Size Series filters.

Internal float drain option is available; consult ROSS for compatibility and model number.

Related Products & Accessories

• MD3 Series Coalescing Filter - Higher-flow coalescing filter (125 scfm) for 1/4 to 1/2 port sizes with polycarbonate or metal bowl options and Oil Vapor Removal capability. https://www.rosscontrols.com/en/series/81-md3-series
• MD4 Series Coalescing Filter - Larger coalescing filter for 3/8 to 3/4 port sizes with flow to 158 scfm for higher-demand pneumatic systems. https://www.rosscontrols.com/en/series/83-md4-series
• Full-Size Series Standard Filters - 5-micron and 40-micron general purpose filters in the Full-Size form factor for upstream pre-filtration ahead of the coalescing stage. https://www.rosscontrols.com/en/categories/40-filters
• Coalescing Filter Element 947K77 - 0.3-micron replacement coalescing element for the Full-Size Series standard bowl configuration. https://www.rosscontrols.com/en/series_variants/512519-947k77
• Full-Size Series FRL Combinations - Factory-assembled filter, regulator, and lubricator combinations for complete Full-Size air preparation stations. https://www.rosscontrols.com/en/categories/44-filter-regulator-and-lubricator

Frequently Asked Questions (FAQ)

Q: What is the difference between the Full-Size Series and the MD3 Series coalescing filters?

A: Both the Full-Size and MD3 Series cover the same port size range (1/4 to 1/2) but differ in flow capacity and bowl construction. The MD3 Series offers higher flow at 125 scfm versus 100 scfm for the Full-Size Series, and the MD3 provides additional metal bowl pressure rating up to 250 psig on manual drain models. The Full-Size Series features the distinctive polycarbonate bowl with steel shatterguard as a standard option and uses a zinc body and aluminum bowl ring. The MD3 uses a die-cast zinc body and offers a polycarbonate bowl with nylon shatterguard as an alternative.

Q: What is the steel shatterguard on the polycarbonate bowl?

A: The steel shatterguard is an external metal guard that surrounds the polycarbonate bowl. In the event of a mechanical impact or overpressure condition that causes the polycarbonate bowl to crack or fracture, the steel shatterguard contains the bowl fragments, preventing them from becoming projectile hazards. This safety feature is standard on the Full-Size Series polycarbonate bowl configuration.

Q: What is the maximum operating pressure of the series?

A: Maximum operating pressure is 150 psig (10 bar) with the polycarbonate bowl and 200 psig (14 bar) with the metal (zinc) bowl. These limits apply to both automatic and manual drain configurations.

Q: Can I convert between standard and extended bowl in the field?

A: The bowl assembly can be replaced in the field if the body and bowl interface are compatible. However, the filter element must also be changed to match the bowl length (standard element 947K77 or 948K77 for standard bowl; R-A103-160L or R-A103-160LE8 for extended bowl). Contact ROSS Controls to confirm field bowl conversion compatibility for your specific model.

Q: What is the bowl liquid capacity?

A: The standard bowl capacity is 8 oz (240 ml). The extended bowl provides greater capacity to accommodate higher condensate volumes in humid environments or systems with high-moisture air supplies.

Q: Does the automatic drain require minimum pressure to operate?

A: Yes. The internal automatic float drain requires a minimum system pressure (approximately 30 psig / 2 bar) to activate. For systems operating below this minimum, specify the manual drain option to ensure condensate is removed at appropriate intervals.

Q: Is the internal float drain option available for the Full-Size Series?

A: Yes, an internal float drain option is available. Contact ROSS Controls for the applicable model number and operating pressure range for the internal float drain configuration of the Full-Size Series.

Q: What replacement elements do I need for the Full-Size Series?

A: For standard bowls: order 947K77 for 0.3-micron or 948K77 for 0.01-micron. For extended bowls: order R-A103-160L for 0.3-micron or R-A103-160LE8 for 0.01-micron. Standard and extended bowl elements are different lengths and cannot be substituted for each other.

Q: How does the differential pressure gauge help with maintenance planning?

A: The differential pressure gauge measures the pressure drop across the coalescing element. As the element collects aerosols and accumulates contamination, resistance to flow increases and differential pressure rises. Monitoring this gauge allows maintenance personnel to replace the element based on actual loading condition rather than a fixed schedule, avoiding both early replacement of serviceable elements and late replacement of overloaded elements that are restricting system flow.

Q: Can the Full-Size Series be used in modular FRL assemblies?

A: Yes. The Full-Size Series is designed for modular assembly with ROSS Full-Size Series regulators and lubricators using ROSS porting block and coupling kit accessories, creating compact integrated FRL stations without intermediate pipe fittings.

Q: What sealing material is used in the series?

A: Seals are Nitrile elastomer, compatible with compressed air service and petroleum-based compressor oils across the rated temperature range of 40 to 175 degrees F (4 to 80 degrees C) for metal bowl configurations.

Q: Where can I get technical support for the Full-Size Series?

A: Contact ROSS Controls at (800) 438-7677 (1-800-GET-ROSS) for sales support and product selection, or 1-888-TEK-ROSS (1-888-835-7677) for technical service. Visit rosscontrols.com for product documentation, dimensional drawings, and the distributor locator.

Installation & Maintenance Guidelines

• Install the filter vertically with the bowl pointing downward to allow condensate to collect at the drain point under gravity. Horizontal or inverted mounting prevents drainage and will lead to downstream liquid carryover.
• Provide 5-micron upstream pre-filtration when the compressed air system has elevated solid particulate contamination from pipe scale, welding debris, or filter element shedding from older upstream filters.
• Verify bowl pressure rating is appropriate for system pressure: polycarbonate bowl up to 150 psig (10 bar), metal bowl up to 200 psig (14 bar). Exceeding bowl pressure ratings is a safety hazard.
• Monitor the differential pressure gauge during system startup to baseline the clean element pressure drop. Establish a replacement threshold, typically 8 to 10 psid, and replace the element when this threshold is reached.
• For modular installation, use ROSS-supplied porting block kits and coupling hardware. Torque coupling bolts to the values specified in ROSS installation instructions. Under-torquing causes joint leakage; over-torquing damages sealing surfaces.
• When performing element replacement, isolate and fully depressurize the filter before removing the bowl. Place a drip pan below the filter to catch accumulated condensate when the bowl is removed.
• Standard bowl elements (947K77 for 0.3 micron; 948K77 for 0.01 micron) and extended bowl elements (R-A103-160L; R-A103-160LE8) are different lengths and are not interchangeable. Confirm the correct element model before ordering.
• For polycarbonate bowl models, avoid cleaning the bowl with aromatic solvents, ketones, or chlorinated cleaners, which cause polycarbonate crazing and reduce impact resistance.

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/82-full-size-series