Mid-Size & Full-Size Mid-Size & Full-Size

Product Overview

The ROSS Controls provides female port blocks for connecting ROSS Mid-Size and Full-Size Series modular FRL assemblies to supply and downstream piping. Female port blocks attach to the inlet and outlet ends of a modular FRL assembly and provide internally threaded ports for direct pipe fitting connections, eliminating the need for separate pipe nipples or adapters at the assembly ends.

The Series is available in four pipe sizes: 1/4, 3/8, 1/2, and 3/4 inch, in both NPTF (models 893K77 to 896K77) and G (BSPP) thread configurations (models D893K77 to D896K77). This complete size range covers all inlet and outlet port size combinations used in Mid-Size and Full-Size FRL assemblies, from the smallest 1/4 inch supply to 3/4 inch high-flow supply lines.

Female port blocks connect to modular FRL unit body faces using the modular interface system of the Mid-Size and Full-Size product families. The female-threaded port accepts standard pipe fittings, elbow fittings, or direct pipe nipple connections at the installation, allowing the engineer maximum flexibility in routing supply and downstream piping.

In a complete modular FRL assembly, two female port blocks are typically required - one at the inlet end and one at the outlet end. If pipe sizes differ at inlet and outlet, two different size port block models are selected. The Series port blocks are a required accessory for every Mid-Size and Full-Size modular FRL installation; the modular FRL units themselves do not include inlet or outlet piping connections.

Key Engineering Features

• Four Pipe Size Options - Available in 1/4, 3/8, 1/2, and 3/4 inch pipe sizes to match the supply and downstream piping of Mid-Size and Full-Size FRL installations across the full range of industrial pneumatic system pipe sizes.
• NPT and G Thread Configurations - NPTF models (893K77 to 896K77) for North American installations; G (BSPP) thread models (D893K77 to D896K77) for international installations, providing global applicability with a single product family.
• Required for Every Modular FRL Assembly - Female port blocks are the mandatory inlet and outlet connection components for Mid-Size and Full-Size modular FRL assemblies. Each assembly requires at least two port blocks - one inlet and one outlet.
• Direct Pipe Fitting Connection - Internally threaded female port provides connection for standard pipe fittings, reducing installation hardware count by eliminating the need for intermediate nipples or adapters at the FRL assembly ends.
• Compatible with Connector Kit 892K77 - The Series female port blocks work in conjunction with the 169 Series connector kit (892K77) to build complete Mid-Size and Full-Size modular FRL assemblies: connector kits join modules, port blocks connect to piping.
• Sixteen Total Models - Eight NPTF models and eight G thread models covering all four pipe sizes in both thread types, providing complete selection coverage with straightforward part number logic.

Technical Specifications

General Specifications

Temperature Ratings

The Series port blocks operate within the temperature range of the Mid-Size and Full-Size FRL assemblies they serve.

Important: Temperature limits are determined by the FRL assembly components (particularly bowl material), not by the port block hardware alone.

Certifications & Compliance

Typical Applications & Industries

General Industrial Pneumatic Supply

• Two 894K77 (3/8 inch NPTF) female port blocks installed at inlet and outlet of a Mid-Size two-unit filter-regulator assembly for a 3/8 inch NPT supply circuit, with the inlet port connected to the supply line and the outlet port connected to downstream distribution.
• Mixed-size port block installation using 895K77 (1/2 inch) at the inlet and 894K77 (3/8 inch) at the outlet of a Full-Size FRL assembly where supply is 1/2 inch NPT and downstream connections are 3/8 inch NPT.
• Replacement of damaged port blocks during FRL assembly service, maintaining the original pipe size and thread type with exact model replacement from the series.

Automotive Manufacturing

• Full-Size modular FRL assemblies at welding cell supply points using 895K77 (1/2 inch NPTF) port blocks at both inlet and outlet for high-flow supply at 1/2 inch NPT circuits feeding multiple welding actuators.
• Mid-Size FRL modular assemblies at individual machine supply drops using 893K77 (1/4 inch NPTF) or 894K77 (3/8 inch NPTF) port blocks to match machine tool pneumatic port sizes.
• International automotive plant FRL installations using D894K77 or D895K77 G thread port blocks for connection to metric piping systems.

Packaging and Assembly Equipment

• Mid-Size FRL modular assemblies at packaging machine supply stations with 893K77 (1/4 inch NPTF) port blocks for compact, efficient pneumatic connection to 1/4 inch supply circuits.
• Full-Size three-unit FRL combinations in centralized air preparation systems for large packaging lines using 896K77 (3/4 inch NPTF) at the inlet for high-flow connection and 895K77 (1/2 inch NPTF) at the outlet for reduced-size downstream distribution.
• Modular FRL assemblies in assembly automation systems where inlet port block size is selected to match the facility's compressed air distribution pipe size and outlet port block matches the machine's pneumatic main supply connection.

Food and Beverage Processing

• Mid-Size modular FRL assemblies in food processing facilities using D893K77 or D894K77 G thread port blocks for integration with metric pipework in European food processing plants.
• Full-Size FRL assemblies at centralized air preparation cabinets in beverage production using 895K77 or 896K77 port blocks for large-bore supply connections to filling, capping, and labeling line pneumatic circuits.

Ordering and Model Number Configuration

The Series female port blocks are selected based on pipe size and thread type. Two port blocks are required per modular FRL assembly - one for the inlet and one for the outlet. Sizes may differ if inlet and outlet pipe sizes are different.

Order two port blocks per modular FRL assembly: one for inlet, one for outlet.

Select port size to match the supply and downstream piping at the installation, not the port size of the FRL unit itself.

For different inlet and outlet pipe sizes, order one port block of each required size.

For NPTF thread (North American): use 893K77, 894K77, 895K77, 896K77.

For G/BSPP thread (International): use D893K77, D894K77, D895K77, D896K77.

Also order 892K77 connector kits for inter-module connections in the same FRL assembly.

Accessories

Series Female Port Block Model Selection Table

Select based on pipe size and thread type.

Required Companion Accessories

The following accessories are needed to complete a Mid-Size or Full-Size modular FRL assembly.

Related Products & Accessories

• 173 Series MD3 and MD4 Port Blocks - Male and female end port accessories for MD3 and MD4 Series modular FRL assemblies - the equivalent port block system for larger MD-series FRL units. https://www.rosscontrols.com/en/series/173-md3-md4
• 169 Series Connector and Bracket Kit - Connector kit (892K77) for joining Mid-Size and Full-Size modular units, and wall mount bracket kit (915K77) for the same assemblies that use Series port blocks. https://www.rosscontrols.com/en/series/169-mid-size-full-size
• 167 Series Mid-Size Bracket Kit - Panel mounting bracket kit for Mid-Size FRL units that use Series port blocks. https://www.rosscontrols.com/en/series/167-mid-size
• 162 Series Full-Size Bracket Kit - Panel mounting bracket kit for Full-Size FRL units that use Series port blocks. https://www.rosscontrols.com/en/series/162-full-size
• 164 Series Electronically Controlled Drains - Timer-controlled drain accessories for the FRL filter assemblies that use Series port block connections. https://www.rosscontrols.com/en/series/164-electronically-controlled-drains

Frequently Asked Questions (FAQ)

Q: How many Series port blocks do I need for one FRL assembly?

A: Two female port blocks are needed per modular FRL assembly - one at the inlet end and one at the outlet end. If the supply pipe size and the downstream pipe size differ, select one port block of each required size.

Q: What is the difference between 893K77 and D893K77?

A: The 893K77 is a 1/4 inch NPTF threaded female port block for North American pipe thread connections. The D893K77 is a 1/4 inch G (BSPP) threaded version for international metric pipe fittings. The 'D' prefix consistently indicates G thread throughout the ROSS FRL accessory catalog.

Q: Can I use a 3/4 inch port block (896K77) on a Mid-Size FRL assembly that has 1/2 inch ports?

A: Port blocks are sized for the inlet/outlet piping, not the FRL unit port size. Using a 3/4 inch port block at a 1/2 inch supply line connection is not standard; match the port block size to the pipe fitting size that connects to the FRL assembly at the installation. If a size transition is needed, use a standard pipe reducer at the piping connection.

Q: Are the series port blocks the same as the 173 Series port blocks?

A: No. The Series port blocks are for Mid-Size and Full-Size Series FRL units. The 173 Series port blocks (R-118-100 and R-118-109 series) are for MD3 and MD4 Series FRL units. The modular interface geometry differs between these product families, making the two series non-interchangeable.

Q: Can I use male pipe fittings directly in the female port block?

A: Yes. The female port block accepts standard male NPT or G thread pipe fittings. This allows direct connection of elbows, reducing bushings, or pipe nipples at the FRL assembly inlet and outlet without additional adapters.

Q: Can the port blocks be reused when an FRL assembly is rebuilt?

A: Yes. Port blocks can be reused if they are in good condition and the threads are undamaged. Inspect threads for corrosion, galling, or damage before reuse. Replace if threads are compromised to avoid leakage.

Q: Is there a pressure rating for the series port blocks?

A: The port blocks are designed for use in ROSS Mid-Size and Full-Size FRL systems. The system pressure rating is determined by the FRL units: 150 psig for polycarbonate bowl assemblies, 200 psig for metal bowl assemblies (Full-Size). Port block hardware is rated for the full FRL system operating pressure range.

Q: Do I need thread sealant when installing Series port blocks?

A: For NPTF thread port blocks, apply PTFE tape or pipe thread compound to the male fitting threads that thread into the female port block. Do not apply sealant inside the port block's female threads. For G thread (BSPP) port blocks, use a flat face seal (O-ring) at the connection; do not use thread sealant on G threads.

Q: Can the series be used for tube connections instead of pipe connections?

A: The Series female port blocks are pipe thread connection accessories. For tube connection at FRL assembly ends, consult the ROSS FRL catalog for tube port kit options (866K77 through 871K77 for BANTAM series, and similar tube port accessories for Mid-Size and Full-Size series).

Q: What if my downstream pipe size is smaller than my supply pipe size?

A: Order two different port blocks: the larger size for the inlet (supply) end and the smaller size for the outlet (downstream) end. This is a common and acceptable configuration when supply is oversized relative to downstream circuit requirements.

Q: Are G thread port blocks available for all four pipe sizes?

A: Yes. G thread variants are available for all four pipe sizes: D893K77 (1/4"), D894K77 (3/8"), D895K77 (1/2"), and D896K77 (3/4"), providing complete G thread coverage matching the NPTF model range.

Q: Where can I find assembly drawings showing how port blocks integrate into a modular FRL?

A: Assembly drawings showing port block installation are in the ROSS FRL catalog (Form A10120) at rosscontrols.com. Contact ROSS Controls at (800) 438-7677 for technical assistance with FRL assembly configuration.

Installation & Maintenance Guidelines

• Select the correct port block pipe size and thread type (NPTF or G) to match the supply and downstream piping at the installation.
• Connect modules using 892K77 connector kits before attaching port blocks at the assembly ends.
• Attach the inlet port block to the FRL assembly inlet modular interface following ROSS installation instructions.
• Attach the outlet port block to the FRL assembly outlet modular interface.
• Connect supply piping to the inlet port block female thread and downstream piping to the outlet port block female thread.
• For NPTF connections: apply PTFE tape or pipe thread compound to male fittings before threading into the port block.
• For G thread connections: use O-ring face seal at the connection; do not use thread sealant.
• Tighten all piping connections to standard pneumatic installation torque values for the pipe size.
• Pressurize the system and verify no leaks at port block interfaces and piping connections.

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 available through ROSS offices in the USA, Canada, Brazil, Germany, France, United Kingdom, India, China, and Japan.

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

For the complete FRL accessories catalog and dimensional drawings, visit rosscontrols.com or contact ROSS Controls at (800) 438-7677.

Download Catalog: https://www.rosscontrols.com/en/series/172-mid-size-full-size