High-Capacity Port Sizes 3/4" to 1"; Flow to 270 scfm (7646 l/min)

Product Overview

The ROSS Controls High-Capacity Series Filter and Lubricator is an inline air preparation unit engineered for high-demand pneumatic systems requiring particulate filtration and oil-mist lubrication at flows up to 270 scfm (7,646 l/min) through 3/4 and 1 inch port connections. Designed for inline mounting on large pneumatic supply headers and machinery with high-flow cylinder circuits, the series addresses applications where mid-size and full-size FRL units cannot meet the airflow requirements of heavy industrial machinery.

The filter section employs a 5-micron rated polyethylene element as standard, removing particulate contamination and coalescing water aerosols to protect downstream pneumatic cylinders, motors, tools, and valves from abrasive wear and corrosion. Optional sintered bronze elements are available in 5-, 20-, and 40-micron ratings for applications requiring chemical compatibility or lower pressure drop at extreme flows. Condensate management is handled through automatic float drain or manual drain configurations, with the automatic drain providing zero-maintenance condensate expulsion during continuous operation.

The wick-feed lubricator mechanism delivers consistent oil-mist generation across the full operating flow range, including a minimum flow requirement of 25 scfm at 3/4 inch port and 35 scfm at 1 inch port for the standard 16-oz (473 ml) bowl configuration. Extended bowl options provide 35-oz (1,035 ml) and 62-oz (1,834 ml) capacity for applications requiring longer intervals between oil refills, with the minimum flow for the 35-oz bowl increasing to 10 scfm. Multiple bowl options include polycarbonate plastic with shatterguard for liquid level visibility and aluminum metal with clear nylon sight glass for elevated temperature and pressure operation.

The oil adjustment mechanism is external and tamper-resistant, allowing delivery rate setting by authorized personnel and removal of the adjusting knob to prevent production interference. The Series serves as the primary point-of-use air preparation component for central compressor room headers, large transfer press circuits, stamping lines, mining equipment, and any application where the combined demands of high flow, reliable filtration, and positive lubrication exceed the capacity of smaller FRL components.

Key Engineering Features

• Inline High-Capacity Design - Engineered for direct inline installation in 3/4 and 1 inch compressed air supply lines serving large pneumatic machinery, compressor room headers, and high-flow cylinder circuits up to 270 scfm.
• Wick-Feed Lubricator Mechanism - Wick-feed design delivers consistent oil-mist generation across the operational flow range, providing reliable lubrication in circuits with variable demand without requiring a fixed minimum flow threshold as high as sight-feed alternatives.
• Multiple Bowl Capacity Options - Standard 16-oz (473 ml) bowl plus extended 35-oz (1,035 ml) and 62-oz (1,834 ml) options allow service interval optimization for different duty cycles, reducing maintenance frequency in high-consumption applications.
• External Tamper-Resistant Oil Adjustment - Adjusting knob set externally and removable after commissioning to prevent unauthorized changes to the oil delivery rate, maintaining specified lubrication levels throughout the production shift.
• Polycarbonate Bowl with Steel Shatterguard - Transparent polycarbonate bowl enables visual monitoring of oil and condensate levels, with the steel shatterguard containing fragments and protecting personnel in the event of bowl damage from over-pressurization or impact.
• Aluminum Bowl with Clear Nylon Sight Glass - Metal aluminum bowl rated for higher pressures and temperatures, with an integrated clear nylon sight glass for oil level monitoring, extending the operating envelope to 200 psig (14 bar) and 175 F (80 C).
• 5-Micron Standard Filtration with Coalescing - Standard 5-micron polyethylene element removes solid particulate and coalesces liquid water from compressed air, protecting the lubricator mechanism and downstream components from contamination at high flow rates.
• Automatic or Manual Drain - Automatic float drain provides maintenance-free condensate expulsion on continuous-duty systems. Manual drain offers positive control of condensate discharge in environments where automatic discharge is restricted.
• Optional Sintered Bronze Filter Elements - 5-, 20-, and 40-micron sintered bronze replacement elements extend chemical resistance and provide filtration rate selection for different upstream air quality conditions.
• Sight-Feed Lubricator Option Available - In addition to the standard wick-feed configuration, sight-feed lubricator variants are available for the High-Capacity platform in selected configurations, providing visual oil delivery confirmation at high flow rates.

Technical Specifications

General Specifications

Temperature Ratings

Temperature ratings depend on bowl material selection. Polycarbonate bowls apply to standard temperature environments. Aluminum metal bowls extend the operating range for higher temperature applications.

Important: Do not use polycarbonate bowls in environments with exposure to solvents, ketones, aromatic hydrocarbons, or halogenated compounds. Specify aluminum metal bowls for all such environments and for ambient temperatures above 125 F (52 C).

Certifications & Compliance

Typical Applications & Industries

Central Compressor Room and Facility-Wide Air Distribution

• Primary supply header air preparation at the compressor room, where a single High-Capacity filter-lubricator conditions the entire compressed air supply before distribution to multiple machine tools, production lines, and pneumatic circuits throughout the facility.
• Zone supply header preparation where the 270 scfm capacity accommodates the combined demand of multiple simultaneous actuator operations across an entire machine bay or production cell.
• Compressor aftercooler and dryer outlet conditioning, providing final particulate removal and lubrication at the facility air supply exit point before the main distribution ring.
• Maintenance shop compressed air supply for pneumatic tools, where the high-capacity unit serves multiple tool stations simultaneously from a central wall-mounted air preparation point.

Heavy Stamping and Metal Forming

• Transfer press main air supply conditioning on large mechanical transfer presses, where the combined demand of part transfer finger drives, die cushion cylinders, and ejector circuits requires sustained high flow with reliable lubrication.
• Progressive die stamping line pneumatic supply preparation, where the series provides filtered and lubricated air to the clutch/brake valve, counterbalance cylinder circuit, and part blow-off systems operating simultaneously.
• Hydraulic press overload protection circuit air supply conditioning, where the air-over-hydraulic overload protection system requires clean, lubricated air for reliable operation of the safety circuit during overload events.
• Metal drawing and deep-drawing press blank holder circuit air supply, where large-bore cylinders maintaining blank holder pressure during drawing operations consume high steady-state airflow demanding the 270 scfm capacity.

Mining and Quarrying Equipment

• Rock drill and down-the-hole hammer air supply conditioning on surface and underground drilling rigs, where high flow rates to large pneumatic hammer mechanisms require consistent lubrication to prevent rapid wear of hammer cylinder components.
• Pneumatic roof bolter supply preparation in underground coal and hard rock mining, where the High-Capacity unit delivers filtered and lubricated air to the combined drilling, bolting, and rotation drives at the working face.
• Longwall mining equipment chain drive and support leg cylinder air supply, where the combined actuation of multiple hydraulic-pneumatic support leg cylinders demands high-flow air preparation at the section air header.
• Surface mining shovel and dragline pneumatic control air preparation, where the aluminum metal bowl is specified for high-temperature ambient environments near diesel engine compartments and heat-generating mechanical systems.

Large Pneumatic Actuator and Valve Control

• Pipeline control valve actuator supply preparation for large quarter-turn pneumatic actuators operating 6 to 12-inch butterfly and ball valves in process piping systems, where the 1-inch port 270 scfm capacity matches the burst flow demand of large-bore actuators.
• Pneumatic diaphragm valve actuator supply for large process control valves in chemical and petrochemical plants, providing filtered and lubricated air to the valve positioner and actuator at the point of use.
• Industrial furnace combustion air damper control actuator supply, where aluminum metal bowls rated to 175 F (80 C) withstand the elevated ambient temperatures near furnace burner control systems.
• Bulk powder and granule handling rotary airlock and diverter valve actuator supply preparation on cement, grain, and mineral processing equipment, where high particulate environments demand reliable 5-micron filtration before actuators.

Foundry and Metal Casting

• Sand mold making machine cylinder supply conditioning on green sand and no-bake molding lines, where the 270 scfm capacity accommodates the high demand of sand squeeze and pattern extraction cylinders operating in high-contamination foundry environments.
• Die casting machine intensifier cylinder and core pull circuit air supply preparation, where large aluminum die casting cells require sustained high airflow to the pneumatic cylinders controlling core pulls and ejector mechanisms.
• Shakeout conveyor and pouring station actuator supply preparation in iron and steel foundries, where aluminum metal bowls resist the elevated ambient temperatures near molten metal handling equipment.
• Shot blast machine conveyor and blast wheel adjusting cylinder supply, providing filtered and lubricated air to resist abrasive media contamination from blast operations.

Rubber and Tire Manufacturing

• Tire press bag bladder inflation and mold clamping cylinder supply conditioning on large tire curing presses, where 1-inch port capacity at 270 scfm matches the burst flow demand of large-bore tire mold clamping cylinders.
• Rubber mixing mill nip adjustment and safety bar cylinder supply preparation, where consistent lubrication of large pneumatic cylinders controlling the roll gap is critical to process consistency.
• Tire building machine supply preparation for belt drum and carcass drum cylinder circuits, where the 62-oz extended bowl option reduces lubricator maintenance frequency on high-production tire building cells operating across three shifts.

Large-Scale Packaging and Palletizing

• Palletizer and layer-forming machine pneumatic cylinder supply on end-of-line packaging systems, where multiple large-bore cylinders operating the layer pusher, row guide, and sheet inserter circuits collectively demand flows at or above 200 scfm.
• Stretch wrapper and shrink tunnel conveyor actuator supply preparation on high-throughput secondary packaging lines, where the combined demand of conveyor stops, reject gates, and film cutting cylinders requires sustained high-capacity air preparation.
• Bag palletizing machine row push and layer transfer cylinder supply conditioning, where the 35-oz or 62-oz extended bowl option reduces maintenance interruptions on continuously operating palletizing systems.

Ordering and Model Number Configuration

The High-Capacity Series Filter and Lubricator is ordered by specifying the model number that encodes port size, bowl material, bowl capacity, and drain type. G (BSPP) thread models carry a 'C' prefix. Extended bowl capacity models use distinct model number sequences.

Standard thread is NPTF. For G (BSPP) threads, prefix the model number with 'C' (example: C5H00B5101).

Polycarbonate bowl models are rated to 150 psig (10 bar) and 125 F (52 C). Aluminum metal bowl models are rated 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 be used from 0 psig.

Standard bowl capacity is 16 oz (473 ml). Extended bowl options of 35 oz (1,035 ml) and 62 oz (1,834 ml) are available for aluminum metal bowls to extend lubricator service intervals.

Minimum flow for lubricator operation varies by bowl size: 25 scfm (11.8 l/s) for 3/4" port 16-oz bowl; 35 scfm (16.5 l/s) for 1" port 16-oz bowl; 10 scfm (4.7 l/s) for 35-oz extended bowl.

Replacement filter elements: standard 5-micron polyethylene (1010K77); optional sintered bronze (5-micron: R-KA109-03E5; 20-micron: R-KA109-03E4; 40-micron: R-KA109-03E3).

Allow 3.1 inches (79 mm) clearance below the unit for bowl removal during maintenance.

Accessories

Replacement Filter Elements

Standard and optional replacement filter elements for the High-Capacity Series. The 5-micron polyethylene element (1010K77) is the standard maintenance replacement. Sintered bronze elements provide chemical resistance and selectable filtration ratings.

Extended Bowl Options

35-oz (1,035 ml) and 62-oz (1,834 ml) aluminum metal bowl assemblies are available for the High-Capacity Series to extend lubricator service intervals on high-flow applications. Extended bowls incorporate two clear nylon sight glass windows for oil level monitoring. Contact ROSS Controls for specific model numbers.

Warning: The minimum airflow required for lubricator operation differs for standard and extended bowl configurations. Verify minimum flow requirements match system operating conditions before specifying extended bowl options.

Mounting Brackets

Wall and pipe-mounting brackets for the High-Capacity inline units allow secure installation on compressor room headers, machine base supports, and wall-mounted distribution panels. Contact ROSS Controls for bracket model numbers applicable to the series.

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 and up to 19 scfm flow, for small pneumatic circuits and 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 flow capacity to 100 scfm. https://www.rosscontrols.com/en/series/136-mid-size-series
• 137 Full-Size Filter and Lubricator Series - Modular filter-lubricator for 1/4 to 3/4 inch ports with wick-feed or sight-feed options and flow capacity to scfm. https://www.rosscontrols.com/en/series/137-full-size-series
• ROSS High-Capacity Pressure Regulators - Inline high-capacity piston pressure regulators for 3/4 and 1 inch ports rated to 300 psig inlet and flows to 800 scfm, for use alongside the series in large air preparation stations. https://www.rosscontrols.com/en/documents
• ROSS High-Capacity FRL Filter Section - Individual High-Capacity filter units for 3/4 and 1 inch port sizes to provide standalone filtration at header points without the integrated lubricator section. https://www.rosscontrols.com/en/documents
• L-O-X Lockout Valves - Lockout valves for safe energy isolation during maintenance, available in sizes compatible with the series for OSHA lockout/tagout compliant air preparation assemblies. https://www.rosscontrols.com/en/series/1287-lockout-valves-15-series

Frequently Asked Questions (FAQ)

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

A: The High-Capacity Series is rated to 270 scfm (7,646 l/min) maximum. This represents the combined filter and lubricator capacity at rated conditions. The filter section flow rate at a given inlet pressure and acceptable pressure drop may be determined from the ROSS Controls High-Capacity filter flow charts, which show pressure drop curves at 100 psig inlet across the full flow range up to 400 scfm.

Q: What is the minimum flow required for the lubricator to operate?

A: Minimum flow requirements depend on bowl configuration. For the standard 16-oz (473 ml) bowl, minimum flow is 25 scfm (11.8 l/s) for the 3/4 inch port and 35 scfm (16.5 l/s) for the 1 inch port. Extended bowl configurations reduce the minimum flow requirement: the 35-oz bowl requires a minimum of 10 scfm (4.7 l/s) and the 62-oz bowl requires 14 scfm (6.6 l/s). Systems with sustained flows below these thresholds may not generate sufficient pressure differential to deliver oil from the wick.

Q: What bowl capacity should I select?

A: Select the standard 16-oz (473 ml) bowl for most high-flow applications where maintenance access is available at regular intervals. Select the 35-oz (1,035 ml) extended bowl when maintenance access is restricted or when extended service intervals are required on high-capacity continuous-duty applications. The 62-oz (1,834 ml) bowl provides the maximum oil reserve for applications running multiple shifts between maintenance interventions, but requires the higher minimum flow of 14 scfm to operate the lubricator mechanism reliably.

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

A: The standard Series uses a wick-feed lubricator, which draws oil through a fibrous wick and delivers it as a mist into the airstream. Wick-feed systems operate reliably across a wide flow range once the minimum threshold is met, without requiring precise needle valve adjustment. Sight-feed variants, also available in the platform for select models, introduce oil through an adjustable needle valve past a visible sight dome, allowing visual confirmation of oil drop rate. Sight-feed is preferred when visual verification is critical for maintenance audits; wick-feed is preferred for simplicity and reliability at variable flow conditions.

Q: Can the series be used in a high-temperature environment?

A: Yes. Specify the aluminum metal bowl with clear nylon sight glass for operating temperatures up to 175 F (80 C) ambient and media. Polycarbonate bowls are limited to 125 F (52 C). In environments with chemical exposure, elevated temperatures, or both, the aluminum bowl provides the appropriate material resistance for the application conditions.

Q: Are extended bowl options available in polycarbonate?

A: Extended bowl capacities (35-oz and 62-oz) are available only in aluminum metal bowl construction. Extended capacity polycarbonate bowls are not cataloged for the High-Capacity Series. For applications requiring liquid level visibility at extended bowl capacity, the aluminum bowl's integrated clear nylon sight glass provides level monitoring capability.

Q: What port thread standards are available?

A: The High-Capacity Series is available in NPTF (standard) and G (BSPP) configurations. G thread models are ordered by adding the prefix 'C' to the model number (example: C5111B6009 for a 1" G thread 16-oz polycarbonate bowl automatic drain sight-feed model).

Q: What optional filter elements are available?

A: In addition to the standard 5-micron polyethylene element (1010K77), sintered bronze elements are available in 5-micron (R-KA109-03E5), 20-micron (R-KA109-03E4), and 40-micron (R-KA109-03E3) ratings. Sintered bronze elements offer improved chemical resistance for applications where the compressed air supply contains lubricants or cleaning agents that would degrade polyethylene, and they are physically robust enough to withstand the high differential pressures possible at 270 scfm flow rates.

Q: How often should the filter element be replaced?

A: Replace the 5-micron filter element (1010K77) when pressure differential across the filter reaches approximately 10 psig (0.7 bar) at system flow rate, or at annual maintenance intervals, whichever occurs first. In high-contamination environments such as foundries, mining operations, or facilities with poorly maintained upstream air treatment, more frequent inspection and replacement is warranted. Sintered bronze elements may be cleaned by back-flushing before replacement to extend service life.

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

A: Polycarbonate bowl: 150 psig (10 bar) maximum. Aluminum metal bowl: 200 psig (14 bar) maximum. Automatic drain models require minimum 15 psig (1 bar) inlet pressure to actuate the float drain valve. Manual drain models can be used from 0 psig inlet pressure.

Q: How do I calculate whether the series meets my flow requirement?

A: Determine the peak simultaneous flow demand of all pneumatic components downstream of the filter-lubricator. Compare this to the 270 scfm rated maximum flow and verify using the ROSS Controls filter flow pressure drop charts, which show pressure drop across the 5-micron element at specific inlet pressures and flow rates. Ensure the pressure drop through the filter does not reduce downstream pressure below the minimum required by downstream components. If flow requirements exceed 270 scfm, contact ROSS Controls for guidance on parallel installations or alternative high-capacity solutions.

Q: What lubricating oil is recommended for the series?

A: Use petroleum-based oil with ISO viscosity grade 32 (ISO VG 32) or lighter, with an aniline point between 180 F and 220 F (82 C to 104 C). Avoid phosphate ester fluids, synthetic lubricants incompatible with nitrile seals, silicone oils, and any fluid with chemical properties incompatible with nylon or polycarbonate bowl components. Confirm compatibility with all seal and bowl materials before using any non-standard lubricant formulation.

Installation & Maintenance Guidelines

• Install the High-Capacity Series with the bowl oriented downward to ensure condensate accumulates at the drain valve and the oil reservoir gravity-feeds the wick or sight-feed mechanism.
• Plan mounting position with a minimum of 3.1 inches (79 mm) of clearance below the bottom of the bowl for removal during element replacement and manual drain maintenance.
• Flow direction must match the directional arrow on the unit body. Reversed installation will impair filter element performance, prevent automatic drain operation, and potentially damage the lubricator mechanism.
• For 3/4 and 1 inch pipe installations, use properly rated pipe fittings and verified thread engagement. NPTF threads require PTFE tape or approved thread compound; hand-tight plus 1.5 turns is the recommended installation torque guidance.
• Verify that inlet pressure meets the minimum 15 psig (1 bar) requirement before startup of automatic drain models. If minimum pressure cannot be guaranteed at startup, specify manual drain configuration.
• Flush the supply line thoroughly before connecting the filter-lubricator. High-capacity applications often involve longer supply runs and larger volume flushing of pipe scale, thread compound, and mill scale.
• Check all downstream components for minimum lubrication requirements to set the lubricator oil delivery rate correctly. Over-lubrication at 270 scfm can flood downstream components with excess oil mist.
• Inspect the filter element (1010K77) and automatic drain operation at each scheduled maintenance interval. In high-contamination environments such as foundries and mining, inspection frequency should increase to weekly or monthly depending on observed contamination loading.
• For extended bowl installations (35-oz and 62-oz), verify that system minimum flow meets the lower threshold (10 scfm for 35-oz bowl) to ensure the lubricator delivers oil at all operating conditions within the production schedule.
• Use only petroleum-based ISO VG 32 or lighter lubricating oil. Do not introduce any fluid incompatible with nitrile seals, nylon bowl rings, or nylon sight domes into the lubricator reservoir.

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, including USA headquarters in Ferndale, Michigan, and offices in 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 data, dimensional drawings, CAD models, and authorized distributor locations.

Replacement filter elements, extended bowl assemblies, seal kits, and complete service parts for the High-Capacity Series are available through ROSS Controls and authorized distributors to support preventive and corrective maintenance programs.

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