High-Capacity Series Port Sizes 3/4" to 1-1/2"; Flow to 500 scfm (14160)

Product Overview

The ROSS Controls High-Capacity Series is the largest lubricator offering in the ROSS FRL product line, engineered for pneumatic systems requiring 3/4 to 1-1/2 inch port sizes and flow rates up to 500 scfm (14,160 l/min). The High-Capacity Series is designed for main compressed air supply headers, high-demand industrial pneumatic networks, and centralized lubrication points serving large numbers of downstream actuators and tools.

The High-Capacity Series is an inline-only design, reflecting the scale of the installations it serves. At these port sizes and flow rates, a modular FRL station is typically replaced by individually installed inline filter, regulator, and lubricator components in the main supply header. The zinc body and inline configuration provide structural integrity appropriate for large-bore pipe installations in industrial environments.

Both sight-feed and wick-feed designs are available in the High-Capacity Series, giving engineers the option to match lubricator behavior to the specific requirements of the downstream equipment. Sight-feed models with external adjusting knob and nylon sight dome provide visual oil delivery confirmation. Wick-feed models use internal adjustment for continuous, consistent lubrication delivery without the need for visual monitoring.

Bowl capacity is the defining specification range of the High-Capacity Series. Standard 16-oz (473-ml) bowls are available in polycarbonate with steel shatterguard or aluminum with nylon sight glass. For applications requiring maximum time between oil refills, extended aluminum bowls are available in 35-oz (1,035-ml) and 62-oz (1,834-ml) capacities, with multiple sight glass windows for oil level monitoring. The 62-oz bowl requires a minimum flow of 14 scfm to operate the sight-feed mechanism reliably, reflecting the larger bowl geometry.

Key Engineering Features

• Highest Flow Capacity in ROSS Lubricator Lineup - 500 scfm (14,160 l/min) maximum flow supports the largest pneumatic supply headers and main air distribution systems in industrial facilities, up to 1-1/2 inch port size.
• Sight-Feed or Wick-Feed Design Options - Sight-feed models provide visual oil delivery confirmation via nylon sight dome with external adjustable knob. Wick-feed models deliver continuous oil with internal adjustment for applications not requiring visual monitoring.
• Multiple Bowl Capacity Options - Three bowl sizes are available: 16-oz (473-ml) standard, 35-oz (1,035-ml) extended, and 62-oz (1,834-ml) large extended. All standard models can be sourced in polycarbonate or aluminum, while 35-oz and 62-oz are aluminum only.
• Polycarbonate or Aluminum Bowl - 16-oz polycarbonate bowl with steel shatterguard rated to 150 psig (10 bar) and 125 F (52 C). Aluminum bowls in all sizes rated to 200 psig (14 bar) and 175 F (80 C). Extended aluminum bowls feature nylon sight glass windows for oil level monitoring.
• External Adjusting Knob (Sight-Feed) - Removable - Sight-feed models include an external adjusting knob to calibrate oil delivery. The knob is removable to provide tamper-resistant protection after setting is established.
• Internal Adjustment (Wick-Feed) - Wick-feed models use internal adjustment to set oil delivery rate, providing tamper-resistant delivery by design without requiring knob removal.
• Quick-Fill Cap Option - Available quick-fill cap option for 1-inch port models allows pressurized oil replenishment without removing the bowl. Reduces maintenance time on high-capacity production air headers.
• Zinc Body with Nylon Bowl Ring - Zinc die-cast body provides structural integrity for large-bore pipe service. Nylon bowl ring provides a durable interface for repeated bowl removal and reinstallation during maintenance.

Technical Specifications

General Specifications

Certifications & Compliance

Typical Applications & Industries

Large Industrial Compressed Air Distribution

• Main compressed air header lubrication at manufacturing facilities where 1 to 1-1/2 inch supply mains distribute lubricated air to all downstream pneumatic circuits throughout a production building. A single High-Capacity lubricator services all downstream tools, actuators, and equipment from the main header.
• Plant-wide pneumatic tool and actuator supply systems in automotive assembly plants, shipyards, and foundries, where 1-1/2 inch supply headers at 400 to 500 scfm require a lubricator rated for these flow conditions without creating a pressure drop bottleneck.
• Compressed air distribution to pneumatic transfer systems in material handling, conveyor drive, and air cushion systems, where large-bore supply pipes require a high-capacity inline lubricator to serve the full system demand.

Pneumatic Rock Drills and Tunneling Equipment

• Underground mining compressed air mains supplying banks of pneumatic rock drills, jacklegs, and stoping hammers, where 1 to 1-1/2 inch supply headers require High-Capacity lubricators with extended bowls sized for the extended intervals between surface maintenance access.
• Tunnel boring and roadheader air supply systems, where large-bore compressed air circuits supply multiple pneumatic functions simultaneously and consistent lubrication of drill steels, rock breaker cylinders, and conveyor actuators requires reliable high-flow oil delivery.
• Shaft sinking pneumatic equipment air supply in deep mining operations, where the 62-oz extended aluminum bowl provides maximum oil capacity for shifts where maintenance access is limited to shift change intervals.

Offshore and Marine Pneumatic Systems

• Offshore platform main instrument air supply manifolds, where 1 to 1-1/2 inch pneumatic headers supply valve actuators, blow-out preventer controls, and process equipment across the platform. High-Capacity lubricators with aluminum bowls handle the marine temperature range and resist corrosion in salt air environments.
• Marine vessel engine room compressed air systems supplying pneumatic starting air, control valve actuators, and compressed air tools, where large-bore headers with inline High-Capacity lubricators centralize lubrication maintenance at the main air distribution point.
• Drilling rig top drive and drawworks pneumatic control circuits, where high-flow demand at large port sizes combined with extended bowl capacity supports continuous drilling operations without frequent lubricator service interruptions.

Steel and Heavy Metal Processing

• Blast furnace and steel plant compressed air main headers supplying pneumatic controls for tuyere valves, taphole drilling equipment, and slag handling actuators, where 1-1/2 inch supply pipes at high flow rates and 200 psig maximum service pressure require aluminum bowl High-Capacity lubricators.
• Continuous caster pneumatic control manifolds serving mold oscillation, secondary cooling zone, and withdrawal roll actuators, where 1 to 1-1/4 inch supply headers at 300 to 500 scfm demand full High-Capacity lubricator flow ratings.
• Hot strip mill pneumatic actuator systems for roll gap, edge guide, and pinch roll controls, where elevated ambient temperatures near the mill require aluminum bowl models rated to 175 F (80 C) for reliable operation in heated production areas.

Petrochemical Plant Pneumatic Instrument Air

• Large chemical plant instrument air distribution headers at 1 to 1-1/2 inch size serving control valve actuator manifolds, where consistent lubrication of diaphragm actuators and positioners across hundreds of control loops is provided from a single centralized High-Capacity lubricator station.
• Refinery flare system pneumatic pilot controls and main plant air supply, where outdoor installations at ambient temperatures up to 175 F (80 C) in hot process environments require aluminum bowl models for continuous service.
• LNG terminal pneumatic valve actuator air supply systems, where large-bore supply headers at extended pressure ratings up to 200 psig benefit from the aluminum bowl High-Capacity lubricator's combined pressure and temperature range.

Power Generation and Utilities

• Power plant service air systems supplying pneumatic cleaning lances, actuator controls, and maintenance tools, where 1 to 1-1/2 inch service air mains require inline High-Capacity lubricators to provide lubrication for all downstream pneumatic service equipment.
• Fossil fuel plant coal handling pneumatic gate and diverter valve actuator air supply, where high-flow demand at large port sizes combined with high ambient temperatures in boiler house environments require aluminum bowl construction.
• Combustion turbine inlet guide vane and bleed valve actuator pneumatic supply, where large-bore actuators demanding consistent, reliable lubrication benefit from the extended bowl capacity of the 35-oz or 62-oz High-Capacity Series models.

Ordering and Model Number Configuration

High-Capacity Series lubricators are selected by port size, design type (sight-feed or wick-feed), bowl material, bowl size, thread type, and fill method. The inline configuration is standard for all models.

Quick-fill cap option (model suffix 011) is available only for 1-inch port size models. 3/4 inch and larger port sizes use fill port only.

Extended 35-oz and 62-oz bowls are available in aluminum (metal) only. Polycarbonate bowl is available only in the 16-oz standard size.

Polycarbonate bowl (5111B) rated to 150 psig (10 bar) and 125 F (52 C). Aluminum bowl (5112B) rated to 200 psig (14 bar) and 175 F (80 C).

Minimum flow requirements vary by bowl size. Confirm that system flow at the lubricator location meets the minimum for the selected bowl size.

Accessories

High-Capacity Series Inline Filters

ROSS High-Capacity Series inline filters for 3/4 to 1-1/2 inch ports. 5-micron polyethylene filter element. Polycarbonate or aluminum bowl with steel shatterguard or nylon sight glass. Automatic or manual drain. Optional differential pressure gauge.

High-Capacity Series Inline Regulators

ROSS High-Capacity Series inline regulators for 3/4 to 1-1/2 inch ports. Piston-type construction. Adjustable outlet pressure. Available in self-relieving and non-relieving configurations.

Extended Bowls (35-oz and 62-oz)

Extended aluminum bowls in 35-oz (1,035-ml) and 62-oz (1,834-ml) capacities are available for all port sizes in the High-Capacity Series. Each provides nylon sight glass windows for oil level monitoring. Maximum rated to 200 psig (14 bar) and 175 F (80 C).

Related Products & Accessories

• MD4 Series Lubricators - Modular sight-feed lubricators for 3/8 to 3/4 inch ports. Transparent dome, removable knob, extended bowl. 200 psig metal bowl rating. Flow to 205 scfm. https://www.rosscontrols.com/en/series/109-md4-series
• 108 Full-Size Series Lubricators - Modular or inline sight-feed and wick-feed lubricators for 1/4 to 3/4 inch ports. 8-oz bowl. Flow to 140 scfm. https://www.rosscontrols.com/en/series/108-full-size-series
• MD3 Series Lubricators - Modular sight-feed lubricators for 1/4 to 1/2 inch ports. Transparent dome, removable knob. 250 psig metal bowl. Flow to 150 scfm. https://www.rosscontrols.com/en/series/107-md3-series
• High-Capacity Series FRL Combination Units - Complete inline FRL assemblies combining High-Capacity filter, regulator, and lubricator for 3/4 to 1-1/2 inch supply mains. https://www.rosscontrols.com/en/series/139-bantam-series

Frequently Asked Questions (FAQ)

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

A: The High-Capacity Series is rated for a maximum flow of 500 scfm (14,160 l/min), the highest flow rating in the ROSS FRL lubricator lineup. This capacity covers the full range of 3/4 to 1-1/2 inch supply header applications in large industrial pneumatic systems.

Q: Is the High-Capacity Series available in a modular configuration?

A: No. The High-Capacity Series is an inline-only product. At port sizes of 3/4 to 1-1/2 inch, FRL components are installed individually in the main supply line rather than in a compact modular station. This is standard practice for large-bore compressed air installations in industrial facilities.

Q: Which bowl size should I specify for my application?

A: Choose the 16-oz (473-ml) standard bowl for applications where regular maintenance access is available and oil consumption can be managed with periodic refilling. Select the 35-oz (1,035-ml) extended bowl for high-consumption applications or locations with limited access between maintenance intervals. Specify the 62-oz (1,834-ml) bowl for the longest possible interval between oil additions, such as underground mining or remote pipeline installations. Note that the 35-oz and 62-oz bowls are available in aluminum only.

Q: What is the minimum flow required for the sight-feed mechanism at each bowl size?

A: The minimum flow varies by bowl size due to differences in bowl geometry and the pressure differential required. For 16-oz bowls: 3/4 port minimum 25 scfm (11.8 l/s); 1 port minimum 35 scfm (16.5 l/s). For 35-oz bowls: minimum 10 scfm (4.7 l/s). For 62-oz bowls: minimum 14 scfm (6.6 l/s). If the system flow at the lubricator location falls below these minimums, the sight-feed mechanism will not draw oil reliably. Select a wick-feed model or a smaller bowl size if the flow condition is marginal.

Q: What is the maximum operating pressure for the High-Capacity Series?

A: Polycarbonate bowl (5111B, 16-oz only): maximum 150 psig (10 bar). Aluminum metal bowls in all sizes (5112B): maximum 200 psig (14 bar). For system pressures above 200 psig, consult ROSS Controls technical support.

Q: What is the temperature limit for metal bowl models?

A: Aluminum metal bowl models are rated for ambient and media temperatures up to 175 F (80 C). This covers most industrial environments, including those near steam lines, heat treating equipment, and industrial boilers. For applications exceeding 175 F, consult ROSS Controls for special configurations.

Q: Is the quick-fill cap available for all port sizes?

A: No. The quick-fill cap option (model suffix 011) is available only for 1-inch port size models. For 3/4 inch and larger port sizes, the standard fill port is used. In high-capacity applications, oil refilling typically requires a brief maintenance shutdown rather than pressurized top-off.

Q: What is the difference between sight-feed and wick-feed in the High-Capacity Series?

A: Sight-feed models deliver oil through a metered needle valve and sight dome, with each oil drop visible in the dome. The external adjusting knob calibrates drop rate to the desired delivery volume. Wick-feed models draw oil continuously by capillary action through a wick and deliver it into the airstream without discrete drop delivery. Wick-feed models use internal adjustment and do not provide visual delivery confirmation but offer steady, pulsation-free oil introduction at any flow rate above minimum.

Q: Can the High-Capacity lubricator be installed horizontally?

A: The standard recommended mounting orientation places the bowl in the downward position. Horizontal or inverted mounting may impair oil reservoir function and sight-feed or wick operation. Consult the ROSS FRL installation instructions for guidance on non-standard orientations, and contact ROSS technical support if your installation requires a non-vertical mounting position.

Q: What lubricant should be used in the High-Capacity Series?

A: Use petroleum-based lubricant with ISO 32 viscosity or lighter and an aniline point between 180 F and 220 F. Standard pneumatic tool oil or air line lubricant meeting these specifications is appropriate. Do not use synthetic lubricants, phosphate-ester fluids, or products containing additives incompatible with nitrile seals. Using incorrect lubricants will degrade seals and shorten lubricator service life.

Q: Is the High-Capacity Series appropriate for outdoor or marine environments?

A: Aluminum bowl models provide better environmental resistance than polycarbonate bowl models for outdoor, marine, and industrial washdown environments. The nylon bowl ring and zinc body are compatible with typical industrial environments. In coastal or salt-air marine environments, protect the unit from direct saltwater spray and inspect periodically for corrosion. For submerged or enclosed washdown-rated applications, consult ROSS Controls technical support.

Q: How does oil delivery scale with system flow rate in the High-Capacity Series?

A: In a sight-feed lubricator, oil delivery rate is proportional to the pressure differential across the lubricator, which increases with flow rate. At higher system flow rates, the lubricator draws more oil per unit time. The external adjusting knob calibrates the baseline delivery rate; at the actual operating flow condition, observe the sight dome to confirm the drop rate is within the desired range. Adjust the knob to reduce or increase delivery as needed. In a wick-feed model, oil delivery is also proportional to flow velocity through the wick contact zone.

Installation & Maintenance Guidelines

• Install the lubricator downstream of the filter and regulator in the air treatment sequence. Introduce only clean, regulated air into the lubricator.
• Mount with the bowl in the downward vertical position. Do not install inverted or horizontally without consulting ROSS installation instructions.
• Verify system pressure does not exceed the bowl pressure rating: 150 psig for polycarbonate bowl, 200 psig for aluminum bowl.
• Verify system flow at the lubricator location meets the minimum flow for the selected bowl size before installation. Undersized flow will result in inadequate lubrication.
• Ensure adequate pipe support is provided for 1 to 1-1/2 inch pipe connections. The lubricator body should not bear the full weight of the piping.
• For sight-feed models, observe the sight dome after startup and adjust the external knob to achieve the target oil drop rate. Remove the knob after adjustment for tamper-resistant operation if required.
• For wick-feed models, set the internal adjustment before installation according to the flow range of the application.
• Use only petroleum-based ISO 32 viscosity or lighter lubricant with aniline point between 180 F and 220 F.
• For extended bowl models (35-oz or 62-oz), verify bowl removal clearance is sufficient for the bowl dimensions before mounting in a panel or confined space.
• Inspect oil level in the bowl at regular intervals appropriate to the application's oil consumption rate. Refill before the bowl is completely empty to prevent air entrainment in the oil delivery mechanism.

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 or (248) 764-1800, or visit rosscontrols.com for product configuration, technical support, and distributor locator services.

Download Catalog: https://www.rosscontrols.com/en/documents/198/ROSS_FRL_Combination_Units_Filter_Regulator_Lubricator.pdf