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

Product Overview

The ROSS Controls provides two essential accessories for Mid-Size and Full-Size modular FRL assemblies: the 892K77 connector kit for joining modular units to one another and to port kits, and the 915K77 bracket assembly kit for wall mounting of complete FRL assemblies. Together these accessories complete the mechanical installation of Mid-Size and Full-Size modular FRL systems.

The 892K77 connector kit is required to interconnect any combination of Mid-Size or Full-Size Series filters, regulators, and lubricators into a modular assembly. Unlike the Bantam Series which uses screw-through end plates, the Mid-Size and Full-Size Series modular units connect using the 892K77 connector hardware at each unit interface, with appropriate port kits completing the inlet and outlet connections.

The 915K77 bracket assembly kit enables wall mounting of complete Mid-Size and Full-Size Series FRL assemblies using two L-shaped metal brackets and four attaching screws. A single bracket can also mount individual filter or lubricator units to a vertical surface. This hardware provides a stable, permanent mount for FRL assemblies without requiring separate mounting structures or custom brackets.

Design engineers specifying Mid-Size and Full-Size FRL assemblies for pneumatic system air preparation will require both the 892K77 connector kits (one per modular junction) and the 915K77 bracket kit for wall-mounted installations. These accessories are essential components in building complete, properly supported FRL assembly systems.

Key Engineering Features

• 892K77 Modular Connector Kit - Connects Mid-Size and Full-Size Series modular FRL units to one another and to inlet/outlet port kits, enabling flexible assembly of filter, regulator, and lubricator combinations at 1/4 to 3/4 inch port sizes.
• 915K77 Bracket Assembly Kit for Wall Mounting - Two L-shaped metal brackets with four attaching screws provide secure wall mounting for complete Mid-Size and Full-Size FRL modular assemblies or individual filter/lubricator units without custom hardware.
• Flexible Single-Unit or Multi-Unit Mounting - One bracket from the 915K77 kit can mount an individual filter or lubricator module; two brackets working together mount a complete multi-unit modular FRL assembly to a vertical surface.
• Designed for Full Modular System Assembly - The 892K77 connector and 915K77 bracket work together with female port blocks (172 Series) to create complete, properly supported modular FRL assemblies with secure supply connections and structural mounting.
• Compatible with Mid-Size and Full-Size Series - Both accessories are compatible with the complete range of ROSS Mid-Size Series (1/4, 3/8, 1/2 ports, up to 105 scfm) and Full-Size Series (3/8, 1/2, 3/4 ports, up to 180 scfm) modular FRL products.
• Standard Hardware Fasteners - Mounting screws included with the 915K77 bracket kit eliminate the need for separate fastener procurement and ensure correct hardware specification for the bracket assembly.

Technical Specifications

General Specifications

Temperature Ratings

The Series hardware accessories are compatible with all Mid-Size and Full-Size Series FRL assemblies within their rated operating temperature ranges.

Important: Temperature ratings are determined by the assembled FRL units. Always verify FRL unit temperature ratings for the target application environment.

Certifications & Compliance

Typical Applications & Industries

Industrial Pneumatic Supply Systems

• Mid-Size filter-regulator combination mounted with 915K77 brackets to a machine frame for a 1/4 to 1/2 inch supply circuit, with 892K77 connectors joining the filter and regulator modules and 172 Series female port blocks at inlet and outlet.
• Full-Size three-unit FRL (filter, regulator, lubricator) assembly wall-mounted with 915K77 brackets on a compressor room wall for centralized air preparation serving multiple machine supply lines at up to 180 scfm.
• Multiple Mid-Size two-unit filter-regulator assemblies wall-mounted with 915K77 brackets at individual machine stations along a production line, each connected with 892K77 kits and fed from a common overhead supply header.

Automotive and Metal Fabrication

• Full-Size FRL assembly wall-mounted at a welding cell supply riser using 915K77 brackets with the full three-unit filter, regulator, lubricator combination connected using 892K77 connectors for weld gun air supply.
• Mid-Size filter-regulator two-unit assembly wall-mounted on press line uprights using 915K77 brackets for individual press supply air preparation at 3/8 to 1/2 inch ports.
• Full-Size FRL assemblies wall-mounted in rows along a transfer line using standardized 915K77 bracket mounting for consistent installation across all machine supply points.

Packaging and Process Equipment

• Mid-Size modular FRL assemblies built with 892K77 connectors and mounted with 915K77 brackets at packaging machine supply risers for regulated, filtered air supply to 1/4 to 1/2 inch pneumatic circuits.
• Full-Size FRL three-unit combination with L-O-X lockout valve wall-mounted using 915K77 brackets at machine isolation points, providing filtration, regulation, lubrication, and energy isolation in a single assembly.

Food and Beverage Processing

• Mid-Size two-unit filter-regulator assemblies with 892K77 connectors and 915K77 wall brackets at individual processing station supply points, providing clean dry air for actuators throughout food handling areas.
• Full-Size FRL assemblies wall-mounted with 915K77 brackets at air preparation cabinets in food processing facilities where large-flow supply is required for multiple pneumatic actuators on filling, capping, and labeling equipment.

Ordering and Model Number Configuration

The Series contains two distinct accessories. The 892K77 connector kit is ordered per modular junction in an FRL assembly; the 915K77 bracket kit is ordered per FRL assembly for wall mounting. Both are needed to complete a properly installed mid-size or full-size modular FRL system.

Order one 892K77 connector kit per modular junction in the FRL assembly (e.g., two kits for a three-unit FRL).

Order one 915K77 bracket assembly kit per FRL assembly for wall mounting (kit includes two brackets and four screws for one assembly).

For inlet and outlet port connections, also order 172 Series female port blocks (893K77 to 896K77) to match pipe size.

The 892K77 connector kit is also compatible with Bantam Series modular units for connecting Bantam units to larger modular assemblies.

For MD3 and MD4 Series modular mounting, use the R-A118-103/R-A118-105 bracket and clamp system specific to those larger modular series.

Accessories

Required Accessories for Mid-Size and Full-Size Modular FRL Assembly

Complete the FRL assembly with connectors and port blocks in addition to the bracket kit.

Related Products & Accessories

• 172 Series Mid-Size and Full-Size Port Blocks - Female port blocks (1/4 to 3/4 inch NPTF and G) for supply and downstream piping connections on Mid-Size and Full-Size FRL assemblies. https://www.rosscontrols.com/en/series/172-mid-size-full-size
• 167 Series Mid-Size Bracket Kit - Panel mounting bracket and panel nut kit for panel-mounting Mid-Size Series FRL units. https://www.rosscontrols.com/en/series/167-mid-size
• 162 Series Full-Size Bracket Kit - Panel mounting bracket and panel nut kit for Full-Size and MD4 Series FRL units. https://www.rosscontrols.com/en/series/162-full-size
• 171 Series High-Relief Regulator Bracket Kit - Bracket assembly for wall mounting high-relief pilot operated regulators at Mid-Size and Full-Size FRL installations. https://www.rosscontrols.com/en/series/171-high-relief-regulator
• 164 Series Electronically Controlled Drains - Electronic timer-controlled drain valves for automatic condensate removal from FRL filter bowls in Mid-Size and Full-Size assemblies. https://www.rosscontrols.com/en/series/164-electronically-controlled-drains

Frequently Asked Questions (FAQ)

Q: What is the 892K77 connector kit used for?

A: The 892K77 connector kit connects Mid-Size Series, Full-Size Series, and Bantam Series modular FRL units to one another. One kit is needed at each inter-module junction. For a two-unit assembly (e.g., filter + regulator), one 892K77 is required; for a three-unit assembly, two 892K77 kits are required.

Q: What is included in the 915K77 bracket assembly kit?

A: The 915K77 kit includes two L-shaped metal brackets and four attaching screws. Two brackets are typically used together to mount a complete FRL modular assembly to a vertical surface. One bracket alone can mount an individual filter or lubricator unit.

Q: Do I need the 892K77 connector kit for every Mid-Size or Full-Size FRL assembly?

A: Yes, whenever two or more modular FRL units are connected in series, 892K77 connector kits are required at each junction. The modular design of Mid-Size and Full-Size units requires this connector hardware to create an airtight, mechanically secure inter-module connection.

Q: Can the 892K77 connect Mid-Size units to Full-Size units in the same assembly?

A: The 892K77 is designed for connections within the same FRL size family. Mid-Size to Full-Size cross-connections are not standard configurations. Contact ROSS Controls at (800) 438-7677 to discuss cross-series connection requirements.

Q: Is the 915K77 bracket required for all FRL installations?

A: The 915K77 is required for wall mounting of FRL assemblies. If the FRL assembly is panel-mounted (through a panel), the 162 Series or 167 Series bracket kits are used instead. The 915K77 is specifically for wall-surface mounting.

Q: How many 892K77 kits do I need for a three-unit FRL assembly?

A: Two 892K77 connector kits are needed for a three-unit FRL assembly - one between the first and second unit, and one between the second and third unit.

Q: Can I use the 915K77 to mount an individual filter or lubricator unit on a wall?

A: Yes. A single bracket from the 915K77 kit can mount an individual filter or lubricator module. For a full multi-unit assembly, both brackets are used together for adequate support.

Q: What port block kits are needed to complete an FRL assembly using the 892K77?

A: After connecting modules with 892K77 kits, you need female port blocks (172 Series: 893K77 to 896K77) at the inlet and outlet ends to connect the assembly to supply and downstream piping. Select the port block that matches your supply pipe thread size.

Q: Are the 892K77 and 915K77 compatible with FRL assemblies that include L-O-X lockout valves?

A: Yes. The 892K77 connector and 915K77 bracket work with Mid-Size and Full-Size FRL assemblies that include modularly connected L-O-X lockout valves, consistent with their use in OSHA-compliant lockout/tagout systems.

Q: Can I add a module to an existing FRL assembly that already uses 892K77 connectors?

A: Yes. The modular design allows adding or removing FRL units. Disassemble the connector at the desired location, insert the new unit, and reconnect with an additional 892K77 connector kit.

Q: Is there a G (BSPP) thread version of the 892K77?

A: The 892K77 connector is an inter-module connector that does not directly interface with pipe threads; it connects FRL module bodies to each other. Port blocks (892K77 through 896K77 and their D-prefix equivalents) provide the NPTF or G thread connections at the assembly ends.

Q: Where do I find the installation instructions for modular Mid-Size and Full-Size FRL assemblies?

A: Assembly instructions including connector kit installation procedures are in the ROSS FRL catalog (Form A10120), available at rosscontrols.com. Contact ROSS Controls at (800) 438-7677 for technical support.

Installation & Maintenance Guidelines

• Select the correct number of 892K77 connector kits: one per inter-module junction in the assembly (e.g., two kits for three units).
• Assemble the FRL units in the desired order (filter first, then regulator, then lubricator if used) using 892K77 connectors at each interface. Follow connector torque specifications in the ROSS FRL catalog.
• Install 172 Series female port blocks (893K77 to 896K77) at the assembly inlet and outlet to match the supply pipe thread size.
• Position the assembled FRL on the mounting surface and mark bracket mounting hole locations using the 915K77 brackets.
• Drill and tap (or use appropriate fasteners for the mounting surface) at the bracket hole locations.
• Attach the 915K77 brackets to the FRL assembly using the included screws, then mount the assembly to the wall surface.
• Connect supply inlet and downstream outlet piping to the female port blocks. Apply appropriate thread sealant to NPT threads.
• Pressurize the system and inspect all module interfaces and port block connections for leaks before placing in service.

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.

Complete Mid-Size and Full-Size FRL assembly documentation and catalog are available at rosscontrols.com.

Download Catalog: https://www.rosscontrols.com/en/series/169-mid-size-full-size