Full-Size Series Port Sizes 1/4" to 3/4"; Flow to 138 scfm (3906 l/min)

Product Overview

The ROSS Controls Full-Size Series Filter and Lubricator is a modular air preparation unit for pneumatic systems requiring simultaneous filtration and lubrication at flow rates up to 138 scfm (3,906 l/min) through 1/4 to 3/4 inch port connections. The Series is purpose-built for modular mounting, integrating directly into ROSS FRL assemblies alongside individual filter, regulator, lockout valve, and lubricator components without intermediate piping requirements.

The filter section provides 5-micron particulate filtration using a standard polyethylene element, removing airborne contaminants and coalescing water aerosols from the compressed air supply before they reach downstream cylinders, valves, and tools. Condensate is managed through automatic or manual drain options, with the automatic float drain providing maintenance-free condensate expulsion in continuous-duty applications.

A distinctive feature of the Full-Size Series is the availability of both sight-feed and wick-feed lubricator configurations within the same product family. The sight-feed design provides visual oil delivery confirmation through the sight dome, critical for commissioning verification and periodic maintenance checks. The wick-feed option delivers consistent lubrication across a broader flow range and lower minimum flow threshold, suitable for circuits with intermittent or variable air consumption. Both lubricator types feature external, tamper-resistant oil adjustment to maintain specified delivery rates in production environments.

Bowl construction options include polycarbonate plastic with steel shatterguard for standard conditions and zinc metal with a clear nylon sight glass for higher pressure and temperature applications. The 8-oz (240-ml) bowl capacity supports extended service intervals between oil refills in medium to high-flow applications. Bowl removal clearance requirements are approximately 3.1 inches (79 mm) below the unit, a factor to account for when planning installation access.

Key Engineering Features

• Modular Mounting Design - Engineered for direct combination with other ROSS FRL components using standard module connecting clamps and port blocks, creating integrated multi-function air preparation assemblies without intermediate piping.
• Dual Lubricator Type Availability - Both sight-feed and wick-feed lubricator configurations are offered within the Full-Size family, allowing selection based on minimum flow requirements, visual confirmation needs, and application duty cycle.
• Sight-Feed with External Visual Indicator - Sight-feed models display oil delivery rate through a clear nylon sight dome, enabling operators and maintenance personnel to verify lubrication function during operation without interrupting production.
• Wick-Feed for Extended Low-Flow Operation - Wick-feed configuration operates reliably at flows from 2 scfm (0.94 l/s) and above, providing consistent oil-mist delivery in circuits with variable or intermittent air consumption patterns.
• External Tamper-Resistant Oil Adjustment - Adjusting knob can be removed after setting the oil delivery rate, preventing unauthorized modification in production environments. Locking key configuration is available on request.
• 5-Micron Standard Filtration - Standard 5-micron polyethylene element (939K77) removes particulate contamination and coalesces condensate. Optional sintered bronze elements available in 5-, 20-, and 40-micron ratings.
• Polycarbonate Bowl with Steel Shatterguard - Transparent polycarbonate bowl provides oil level visibility while the steel shatterguard contains fragments in the event of bowl damage, protecting personnel from injury.
• Zinc Bowl with Clear Nylon Sight Glass - Metal zinc bowl rated to 200 psig (14 bar) and 175 F (80 C), with an integrated clear nylon sight glass for oil level monitoring at elevated pressure and temperature conditions.
• 8-Oz Bowl Capacity - The 240-ml lubricator reservoir supports extended operating intervals between oil refills, reducing maintenance frequency in high-volume production environments.
• Port Sizes 1/4 to 3/4 Inch - Full port range from 1/4 to 3/4 inch within a common head and bowl platform, simplifying inventory management and spare parts stocking across a range of machine sizes.

Technical Specifications

General Specifications

Temperature Ratings

Temperature ratings depend on bowl material. Polycarbonate bowls are suitable for standard temperature conditions. Zinc metal bowls extend the operating range significantly.

Important: Polycarbonate bowls must not be exposed to halogenated hydrocarbons, ketones, aromatic solvents, or strong chemicals. Use zinc metal bowls in such environments and whenever ambient temperatures exceed 125 F (52 C).

Certifications & Compliance

Typical Applications & Industries

General Industrial Automation

• Pneumatic actuator supply conditioning for large-bore cylinders used in material handling, clamping, and indexing applications where 3/4 inch port capacity at up to 138 scfm provides adequate flow for fast-cycling actuators.
• Air motor and pneumatic drill supply conditioning on production line tooling fixtures, where the wick-feed option ensures lubrication continuity during variable-speed operation without minimum flow interruptions.
• Multi-cylinder pneumatic control systems supply preparation where the modular format allows the series filter-lubricator to be combined with a regulator and lockout valve in a single compact FRL station.
• Pneumatic conveyor system drive cylinder supply, protecting large-bore conveyor stop gate and pusher cylinders from particulate contamination generated in foundry, metalworking, and mineral processing environments.
• Pneumatic press and stamping machine actuator supply, where the 8-oz (240-ml) bowl capacity reduces maintenance frequency on high-flow presses cycling continuously across production shifts.

Automotive and Heavy Equipment Manufacturing

• Body-in-white assembly fixture clamping cylinder supply on automotive production lines, where 3/4 inch port filter-lubricators protect the large-bore cylinders securing body panels during welding and assembly operations.
• Robotic arc welding station air supply preparation, filtering and lubricating compressed air used for wire feed motor drives, torch cooling air, and pneumatic wrist joints on welding robots.
• Chassis assembly line air wrench and impact tool supply conditioning, where the sight-feed lubricator provides visual confirmation of oil delivery to high-torque pneumatic tools used in suspension and brake system assembly.
• Paint shop conveyance cylinder supply conditioning, with zinc metal bowl specified for elevated ambient temperatures in proximity to paint cure ovens operating at 140 F (60 C) and above.
• Final assembly torque audit tool supply preparation on powertrain and chassis assembly, where consistent filtration and lubrication directly impacts torque tool repeatability and calibration interval compliance.

Food Processing and Beverage Production

• High-speed bottling line actuator supply conditioning, where the 138 scfm flow capacity of the series supports simultaneous operation of bottle rinser, filler, capper, and labeler pneumatic cylinder circuits.
• Aseptic fill line pneumatic valve and cylinder supply preparation, where 5-micron filtration removes contamination that could compromise seal surfaces on sterile filling equipment.
• Brewery and winery packaging line pneumatic supply, where manual drain configuration is specified to prevent automatic condensate discharge during sanitization operations.
• Frozen food processing conveyance and portioning machine cylinder supply, where consistent lubrication at temperatures as low as 40 F (4 C) maintains cylinder stroke consistency across temperature cycling.

Woodworking and Furniture Manufacturing

• CNC router and point-to-point boring machine pneumatic workholding clamp supply, where filtered and lubricated air at 3/4 inch port capacity protects the vacuum and pressure clamp cylinders maintaining workpiece position during machining.
• Edge banding machine cylinder supply conditioning on furniture production lines, where the modular Series format integrates into the machine base air preparation station alongside the regulator.
• Cabinet assembly pneumatic stapler and nailer supply conditioning, where consistent filtration prevents debris from tool exhaust from contaminating the lubricated air supply to finish-quality pneumatic nailers.
• Veneer press and laminating machine clamping cylinder supply, where the 8-oz oil bowl supports extended production runs without interruption for lubricator maintenance.

Mining and Heavy Industry

• Rock drill and pneumatic hammer tool supply conditioning in underground and surface mining operations, where the zinc metal bowl withstands the elevated temperatures and harsh conditions of mining environments.
• Bulk material handling valve actuator supply preparation on conveyor transfer stations, where 5-micron filtration protects butterfly valve and knife gate actuators from abrasive dust contamination.
• Pneumatic vibrator supply conditioning on bulk storage bin discharge systems, where consistent lubrication of the vane-type air vibrator extends service life in high-contamination environments.
• Crushing and screening plant pneumatic control supply preparation, where the Full-Size Series flow capacity matches the large-bore cylinders used to operate crusher jaw settings and screen tensioning systems.

Plastics Processing and Rubber Manufacturing

• Injection molding machine hydraulic valve solenoid pilot air supply conditioning, where filtered and lubricated pilot air maintains solenoid valve performance in the high-temperature environment of a molding machine control cabinet.
• Blow molding machine mold clamping and stretch rod cylinder supply preparation, where 138 scfm flow capacity supports the high-speed cylinder circuits on multi-cavity blow molding systems.
• Rubber calendering machine roll-separation cylinder supply conditioning, where zinc metal bowls withstand the elevated ambient temperatures characteristic of heated roll nip areas in rubber processing.

Ordering and Model Number Configuration

The Full-Size Series Filter and Lubricator is ordered by model number specifying port size, port type (threaded or pipe nipple), bowl material, and drain type. Sight-feed and wick-feed lubricator options are distinguished by model number digit. G (BSPP) thread models carry a 'C' prefix.

Standard thread is NPTF. For G (BSPP) threads, prefix the model number with 'C' (example: C5F11B3101).

Polycarbonate bowl models are rated to 150 psig (10 bar) and 125 F (52 C). Zinc metal bowl models extend to 200 psig (14 bar) and 175 F (80 C).

Automatic drain models require minimum 15 psig (1 bar) inlet pressure. Manual drain models can operate from 0 psig.

Both threaded port and pipe nipple port configurations are available. Pipe nipple models (5F00Bxxxx) include short nipple extensions for piped connections; threaded port models (5F11Bxxxx) use standard tapped ports.

Quick-fill cap option is available as an alternative to the standard fill port for oil reservoir refill without system depressurization.

Replacement filter elements: standard 5-micron polyethylene (939K77); optional sintered bronze (5-micron: R-KA103-03E5; 20-micron: R-KA103-03E4; 40-micron: R-KA103-03E3).

Minimum flow for lubricator operation is 2 scfm (0.94 l/s). Allow 3.1 inches (79 mm) clearance below the unit for bowl removal.

Accessories

Replacement Filter Elements

Replacement filter elements for the Full-Size Series. Standard 5-micron polyethylene element is the most commonly stocked. Sintered bronze elements offer higher efficiency and chemical compatibility for demanding applications.

Modular Assembly Hardware

Module connecting clamps, brackets, male and female end ports, and extra port blocks enable assembly of the series into multi-function modular FRL stations. Contact ROSS Controls for the current accessory catalog.

Quick-Fill Cap

Optional quick-fill cap for the lubricator reservoir allows oil refill while the unit remains under pressure and in service, minimizing maintenance downtime on continuous-duty production systems.

Related Products & Accessories

• 135 Miniature Filter and Lubricator Series - Compact inline filter-lubricator for 1/8 and 1/4 inch ports with wick-feed lubrication, up to 19 scfm, for space-constrained installations. https://www.rosscontrols.com/en/series/135-miniature-series
• 136 Mid-Size Filter and Lubricator Series - Modular filter-lubricator for 1/4 to 1/2 inch ports with sight-feed lubrication and up to 100 scfm flow capacity. https://www.rosscontrols.com/en/series/136-mid-size-series
• 138 High-Capacity Filter and Lubricator Series - Inline filter-lubricator for 3/4 and 1 inch ports delivering up to 270 scfm for the highest flow industrial applications. https://www.rosscontrols.com/en/series/138-high-capacity
• MD4 Series Full-Size FRL Combination - Complete Filter, Regulator, and Lubricator combination in the Full-Size platform for 3/8 to 3/4 inch ports at up to 205 scfm, integrating regulator functionality. https://www.rosscontrols.com/en/series/144-md4-series
• ROSS Full-Size Pressure Regulators - Modular pressure regulators in the Full-Size format for integration with the series in complete FRL assemblies. https://www.rosscontrols.com/en/documents
• L-O-X Lockout Valves - Modular lockout valves for safe energy isolation compatible with Full-Size FRL assemblies, meeting OSHA lockout/tagout requirements. https://www.rosscontrols.com/en/series/1287-lockout-valves-15-series

Frequently Asked Questions (FAQ)

Q: What is the maximum flow capacity of the Full-Size Series?

A: The Full-Size Series delivers up to 138 scfm (3,906 l/min) through 1/4 to 3/4 inch port sizes. The lubricator section is rated to 140 scfm at 100 psig inlet pressure. Flow capacity varies by port size and inlet pressure; consult the ROSS Controls flow charts for pressure drop at specific operating conditions.

Q: What is the difference between the sight-feed and wick-feed lubricator options?

A: The sight-feed lubricator draws oil through an adjustable needle valve past a clear sight dome, providing visual confirmation of the oil drop rate during operation. It requires a minimum flow of approximately 2 scfm to operate reliably. The wick-feed lubricator uses a fiber wick to draw oil into the airstream without a needle valve, providing consistent oil mist delivery across a wide flow range. Both types are external tamper-resistant. Sight-feed is preferred when visual verification of oil delivery is required; wick-feed is preferred for circuits with variable or intermittent flow.

Q: Can I switch between sight-feed and wick-feed in the same head assembly?

A: The sight-feed and wick-feed lubricator cartridges are distinct assemblies. The head assembly is the same for both, but the internal cartridge and bowl ring differ. To convert from one type to the other, the cartridge and associated parts must be replaced. Consult ROSS Controls for service kit availability for each lubricator type.

Q: What is the bowl capacity and typical refill interval?

A: The lubricator reservoir holds 8 oz (240 ml). Refill interval depends on operating flow rate and oil delivery rate setting. At a typical delivery rate and moderate continuous flow, an 8-oz bowl may provide 16 to 48 hours of operation. At high continuous flows, the interval is shorter. Monitor oil level through the polycarbonate bowl or via scheduled maintenance intervals for zinc bowl installations.

Q: Are pipe nipple port models available in addition to threaded port models?

A: Yes. The Full-Size Series is available in both threaded port (5F11Bxxxx) and pipe nipple port (5F00Bxxxx) configurations. Pipe nipple models include short nipple extensions suitable for piped connections. Threaded port models use standard NPTF or G tapped ports. Both configurations are available in all port sizes and bowl material options.

Q: What is the pressure rating for each bowl type?

A: Polycarbonate bowl with steel shatterguard: 150 psig (10 bar) maximum, with automatic drain requiring minimum 15 psig. Zinc metal bowl with sight glass: 200 psig (14 bar) maximum for both automatic and manual drain. Select zinc metal bowls for systems operating above 150 psig or above 125 F (52 C) ambient temperature.

Q: How do optional sintered bronze filter elements differ from the standard polyethylene element?

A: The standard 5-micron polyethylene element provides effective filtration for most industrial compressed air systems. Optional sintered bronze elements (5-micron: R-KA103-03E5) offer higher structural rigidity, improved chemical resistance to hydrocarbons and solvents that would degrade polyethylene, and are washable and reusable. The 20-micron (R-KA103-03E4) and 40-micron (R-KA103-03E3) sintered bronze options allow coarser filtration where lower pressure drop is prioritized over fine filtration.

Q: What is the minimum clearance needed below the unit for bowl removal?

A: Allow a minimum of 3.1 inches (79 mm) below the bottom of the unit for bowl removal. This clearance is in addition to the unit's installed height. For combined filter-lubricator assemblies, account for the full 7.1-inch (180 mm) height plus the 3.1-inch clearance requirement when planning mounting positions.

Q: Can the series be used in an FRL assembly with a ROSS regulator and lockout valve?

A: Yes. The modular design of the Full-Size Series is intended for combination with ROSS Full-Size modular regulators, lockout valves, and other FRL components. Module connecting clamps (R-A118-105) connect the units at their modular faces. Complete FRL assembly configurations including filter, regulator, lubricator, and lockout valve are available from ROSS Controls.

Q: What thread standards are supported?

A: The Full-Size Series is available in NPTF (standard) and G (BSPP) thread configurations. G thread models are ordered by adding the prefix 'C' to the model number. All port sizes from 1/4 to 3/4 inch are available in both thread standards.

Q: Does ROSS offer an electronic drain for the series?

A: The Full-Size Filter-Lubricator series offers automatic and manual drain configurations. Electronic drain options are available on some ROSS Full-Size FRL combination units (FRL filter-regulator-lubricator assemblies) but may not be standard on the standalone Series filter-lubricator. Contact ROSS Controls at (800) 438-7677 to confirm electronic drain availability for the specific configuration required.

Q: What is the recommended lubrication rate for pneumatic cylinders?

A: Lubrication rate recommendations depend on the specific pneumatic component manufacturer's requirements. As a general guideline for standard industrial pneumatic cylinders with nitrile seals, a delivery rate of 1 drop of oil per 20 to 50 scfm of airflow at the sight dome is a starting point. Adjust based on observed cylinder performance, seal condition during maintenance inspections, and component manufacturer recommendations.

Installation & Maintenance Guidelines

• Mount the Full-Size Series with the bowl oriented downward to ensure condensate collects at the drain and oil remains accessible to the lubricator mechanism.
• Plan mounting position with a minimum of 3.1 inches (79 mm) clearance below the bowl for removal during element replacement and filter maintenance.
• Match airflow direction to the arrow marked on the unit body. Reverse installation impairs filtration and drain performance.
• For modular assemblies, align all module faces before torquing module connecting clamp hardware. Internal port misalignment creates cross-leakage and reduces effective flow cross-section.
• Use PTFE thread sealant tape on NPTF threads; hand-tight plus 1.5 turns is sufficient for most thread sizes. Do not over-torque.
• Verify automatic drain operation during initial system pressurization by observing condensate discharge. If no discharge occurs after extended operation with known condensate loading, inspect the drain float mechanism.
• Flush the system supply line before connecting the filter-lubricator to prevent installation debris from loading the filter element on startup.
• For pipe nipple port models, use appropriate nipple engagement depth and thread sealant to prevent leakage at the pipe-to-fitting interface.
• Use petroleum-based lubricating oil with ISO VG 32 or lighter viscosity. Avoid phosphate esters, synthetic lubricants incompatible with nitrile seals, and any oil that reacts with the acetal adjusting knob or nylon sight dome.
• Inspect and replace the filter element (939K77) when pressure differential exceeds 10 psig (0.7 bar) at system flow rate, or at each annual maintenance interval.

Warranty & Global Support

ROSS Controls provides a one-year warranty on all products against defects in material and workmanship from the date of purchase.

Technical support is available through ROSS Controls global offices: USA (Ferndale, Michigan headquarters), Canada, Brazil, Germany, France, United Kingdom, India, China, and Japan.

Contact ROSS Controls USA at (800) 438-7677 or rosscontrols.com for product configuration, technical data, dimensional drawings, and authorized distributor locations.

Replacement filter elements (939K77 and sintered bronze options), seal kits, and bowl assemblies are available as spare parts through ROSS Controls and authorized distributors.

Download Catalog: https://www.rosscontrols.com/en/documents/196?filename=ROSS_FRL_Combination_Units_Filter_Lubricator.pdf