Full-Size Series Port Sizes 1/4" to 3/4"; Flow to 140 scfm (3965 l/min)

Product Overview

The ROSS Controls Full-Size Series is a Filter/Regulator and Lubricator combo that consolidates particulate filtration, downstream pressure regulation, and lubricator in a single modular assembly for high-demand pneumatic systems. With port sizes spanning 1/4" to 3/4" and a maximum flow capacity of 140 scfm (3965 l/min), the Full-Size Series is designed to handle the air preparation requirements of larger pneumatic circuits including machine tool centers, automated production lines, and industrial process equipment.

The filter section provides bowl options in polycarbonate plastic with steel shatterguard for impact-resistant visual condensate monitoring, or zinc metal bowls with clear nylon sight glass for higher-pressure and temperature applications. Three drain configurations are available: automatic internal drain, manual drain, and external automatic drain. The external automatic drain option allows remote mounting of the drain valve in installations where the filter body is not accessible for periodic manual operation.

The diaphragm-type regulator provides precise, low-hysteresis pressure control that maintains stable downstream pressure through varying flow demand conditions, a critical requirement in applications where pressure fluctuations affect process quality or actuator repeatability. Both self-relieving and non-relieving variants are available. A pressure gauge is provided as standard on the regulator body.

The lubricator section of the Full-Size Series offers either a sight-feed or a wick-feed design. The sight-feed lubricator provides visible oil delivery confirmation through a transparent dome. The wick-feed lubricator delivers oil passively without requiring a sight dome. Both types are integrated into the modular assembly and deliver petroleum-based lubricant to downstream pneumatic valves, actuators, and air tools. The modular design permits individual sections to be serviced, replaced, or reconfigured independently.

Key Engineering Features

• High-Flow Capability to 140 scfm - Rated for flow up to 140 scfm (3965 l/min) at port sizes through 3/4", making the series applicable to large pneumatic circuits and high-flow production equipment.
• Sight-Feed or Wick-Feed Lubricator - Choice of sight-feed lubricator for visible oil delivery confirmation or wick-feed lubricator for passive, maintenance-friendly oil delivery without a sight dome.
• Diaphragm-Type Regulator - Provides low-hysteresis, precise pressure regulation with stable output across varying flow conditions, suitable for both general industrial and precision pneumatic applications.
• Modular Mounting - Modular design allows individual filter, regulator, and lubricator sections to be serviced, replaced, or reconfigured without disturbing the installed pipe connections.
• Three Drain Options - Automatic internal drain, manual drain, and external automatic drain provide complete flexibility for condensate management in any installation configuration.
• Polycarbonate with Shatterguard or Zinc Bowl - Polycarbonate bowl with steel shatterguard provides visual condensate monitoring with impact protection; zinc metal bowl with nylon sight glass extends capability for higher-pressure and temperature environments.
• Self-Relieving or Non-Relieving Regulator - Self-relieving version vents excess downstream pressure when the set point is reduced; non-relieving retains downstream pressure for closed-system requirements.
• Standard Pressure Gauge - Integral pressure gauge provides direct visual indication of regulated output pressure on the assembly.

Technical Specifications

General Specifications

Certifications & Compliance

Typical Applications & Industries

Large Machine Tool and Metalworking

• Machining centers, boring mills, and flexible manufacturing cells with 3/4" compressed air supply lines requiring full air preparation at up to 140 scfm.
• Transfer line and production line pneumatic systems supplying multiple machine stations from a central air preparation point at 1/2" or 3/4" main supply headers.
• Heavy-duty stamping and forming presses with pneumatic clutch-brake controls, die cushion circuits, and tooling change actuators requiring high-flow conditioned air.
• CNC turning and grinding centers with multiple pneumatic consumers including part ejection, coolant management, workholding, and spindle air seals.

Automotive Manufacturing

• Automotive body assembly lines with welding robots, transfer fixtures, and clamping actuators requiring high-flow air preparation at 3/4" supply connections.
• Engine assembly and powertrain test cells where 140 scfm FRL conditioning protects pneumatic tooling and control valves across large-volume production operations.
• Paint shop air preparation for pneumatic conveyors, booth doors, and material handling equipment where clean, regulated, lubricated air is required at high flow rates.
• Final assembly lines with pneumatic torque tools, lifts, and ergonomic assists requiring central FRL conditioning at main air drops.

General Heavy Industry

• Steel mill and metals processing pneumatic actuators, including slab guides, roller drives, and shear actuators, where high-flow air preparation is required at central supply points.
• Cement, aggregate, and mining equipment pneumatic systems with 3/4" supply connections requiring reliable air preparation with external automatic drain for remote or overhead installation.
• Paper and pulp mill machine section air preparation where 140 scfm capacity handles the aggregate demand of multiple actuators on each machine module.

Process and Petrochemical

• Process plant instrument air headers conditioning compressed air for multiple pneumatic control valves and positioners from a single modular FRL station.
• Compressor station auxiliary air preparation for pneumatic control actuators, with external automatic drain to enable installation in locations where manual drain access is impractical.
• Chemical plant process air circuits where precise diaphragm regulation maintains stable pneumatic actuator force in variable-demand operating conditions.

Packaging and Food and Beverage

• High-capacity packaging lines with case erectors, palletizers, and strapping machines requiring full air preparation at 1/2" or 3/4" supply connections.
• Food and beverage filling and capping lines where the zinc bowl with nylon sight glass provides the temperature rating needed for hot processing environments.
• Distribution center sortation and material handling systems where the external automatic drain option simplifies maintenance in overhead or wall-mounted FRL installations.

Energy and Power Generation

• Power plant control air systems for turbine and boiler auxiliary pneumatic actuators requiring high-flow, reliable air preparation at central header connections.
• Wind turbine nacelle pneumatic systems where modular FRL design facilitates maintenance in confined nacelle spaces without complete disassembly.

Ordering and Model Number Configuration

The ROSS Full-Size Series FRL combo is configured by selecting port size, bowl material, drain type, lubricator type, and regulator function. Contact ROSS Controls at (800) 438-7677 or visit rosscontrols.com for configuration assistance and model number generation.

Specify port size, bowl material (polycarbonate with shatterguard or zinc), drain type (internal automatic, manual, or external automatic), lubricator type (sight-feed or wick-feed), and regulator function (self-relieving or non-relieving) when ordering.

NPT thread is standard. Confirm G (BSPP) thread availability with ROSS Controls at time of order.

The external automatic drain option includes a remotely mountable drain valve assembly. Confirm installation clearances before specifying this option.

For applications not requiring lubrication, refer to the ROSS Controls 70 Full-Size Series filter/regulator.

Accessories

Mounting Brackets

Panel and pipe mounting brackets for the Full-Size Series FRL are available to secure the modular assembly to machine frames, support structures, and standard pipe stands. Contact ROSS Controls for compatible bracket model numbers.

Replacement Filter Elements

Replacement filter elements in 5-micron and 40-micron grades maintain rated filtration performance in the Full-Size Series filter section.

External Automatic Drain Assembly

For installations where the filter bowl is in an inaccessible location, the external automatic drain assembly remotely mounts the float-actuated drain valve at an accessible point.

Replacement Bowls and Seals

Replacement polycarbonate and zinc bowls with associated seals are available as service parts for the Full-Size Series.

Related Products & Accessories

• 70 Full-Size Series Filter/Regulator - Standalone Full-Size Series filter/regulator for applications requiring filtration and regulation without lubrication. https://www.rosscontrols.com/en/series/70-full-size-series
• MD3 Series FRL Combo - MD3 Series FRL combo for same port range with diaphragm regulator and expanded bowl and drain options. https://www.rosscontrols.com/en/series/142-md3-series
• MD4 Series FRL Combo - MD4 Series FRL combo for port sizes 3/8" to 3/4" with higher flow up to 205 scfm. https://www.rosscontrols.com/en/series/144-md4-series
• 141 Mid-Size Series FRL Combo - Mid-Size FRL combo for port sizes 1/4" to 1/2" with piston regulator and sight-feed lubricator. https://www.rosscontrols.com/en/series/141-mid-size-series
• 139 Bantam Series FRL Combo - Bantam Series FRL combo for smaller port sizes 1/8" and 1/4". https://www.rosscontrols.com/en/series/139-bantam-series

Frequently Asked Questions (FAQ)

Q: What is the Full-Size Series FRL combo?

A: The Full-Size Series is a single modular assembly that removes particulate contamination from compressed air, regulates downstream pressure to the set value, and delivers lubrication to downstream pneumatic components. It handles port sizes from 1/4" to 3/4" and flow up to 140 scfm (3965 l/min).

Q: What port sizes are available?

A: The Full-Size Series is available in 1/4", 3/8", 1/2", and 3/4" port sizes.

Q: What is the maximum rated flow?

A: The Full-Size Series handles up to 140 scfm (3965 l/min), the highest capacity in this group for the 1/4" to 3/4" port range.

Q: What lubricator types are available?

A: The Full-Size Series can be ordered with a sight-feed lubricator, which provides visible confirmation of oil delivery through a transparent sight dome, or a wick-feed lubricator, which delivers oil passively without a sight dome for simplified operation.

Q: What drain configurations are available?

A: Three options are available: internal automatic drain uses a float-actuated valve inside the filter bowl to drain condensate automatically; manual drain requires the operator to open the valve; external automatic drain mounts the float-actuated drain valve remotely for installations where the filter body location is not accessible.

Q: What are the bowl material options?

A: Polycarbonate with steel shatterguard is rated to 150 psig and 125 degrees F and provides visual condensate level monitoring with impact protection. Zinc with clear nylon sight glass is rated to 200 psig and 175 degrees F for higher-pressure and higher-temperature environments.

Q: Why use the external automatic drain?

A: The external automatic drain is specified when the filter assembly is installed in an overhead, confined, or otherwise inaccessible location where manual drainage is impractical. The drain valve is remotely mounted at a reachable position while the filter body remains in the line.

Q: What type of regulator does the Full-Size Series use?

A: The Full-Size Series uses a diaphragm-type regulator, which provides low-hysteresis, precise pressure regulation. This design is well suited to applications requiring stable output pressure across variable flow demand conditions.

Q: What is the temperature limit for the zinc bowl?

A: The zinc bowl with nylon sight glass is rated for operating temperatures up to 175 degrees F (80 degrees C) and 200 psig. This makes it appropriate for installations in elevated-temperature industrial environments such as near heat-generating equipment or in warm climates.

Q: Can I specify a non-relieving regulator?

A: Yes. The non-relieving regulator option does not vent downstream pressure when the set point is reduced. It is specified for closed systems where releasing compressed air to atmosphere is not acceptable.

Q: How is the output pressure adjusted?

A: Pull the regulator adjustment knob upward to unlock. Rotate clockwise to increase pressure and counterclockwise to decrease. Observe the integral pressure gauge and push the knob down to lock once the desired set point is reached.

Q: What lubricant is compatible with this assembly?

A: Use petroleum-based oil with ISO 32 viscosity or lighter. Do not use synthetic ester-based or phosphate-ester lubricants, which are incompatible with the standard nitrile seals in the assembly.

Q: How often should the filter element be replaced?

A: Replace the filter element on schedule or when elevated differential pressure across the filter indicates element saturation. In high-particulate environments replacement intervals will be shorter.

Q: Where can I get documentation and order information?

A: Product catalogs, data sheets, and installation instructions for the Full-Size Series are available at rosscontrols.com. Contact ROSS Controls at (800) 438-7677 for configuration support.

Installation & Maintenance Guidelines

• Install with bowls oriented downward for proper condensate accumulation and drainage.
• Align the flow direction indicator on the assembly body with the compressed air supply flow direction.
• Mount in a location providing access to the filter bowl drain, lubricator fill, pressure gauge, and regulator knob. For external automatic drain installations, route the drain tubing to a location suitable for condensate discharge.
• Apply thread sealant to pipe port connections and tighten to the specified torque. Do not overtighten polycarbonate or shatterguard connections.
• Confirm that inlet pressure does not exceed 150 psig for polycarbonate bowls or 200 psig for zinc bowls.
• Confirm that ambient and air temperature remain within the rated range for the bowl material.
• Fill the lubricator bowl with petroleum-based ISO 32 or lighter oil before first use.
• Pressurize slowly after installation and check all connections, bowl seals, and drain valves with leak detection solution.
• Set regulated output pressure by pulling the knob up, adjusting to the desired gauge reading, and pushing the knob down to lock.
• For sight-feed lubricators, observe the sight dome after start-up to confirm oil delivery. Adjust the feed rate as required.
• For wick-feed lubricators, confirm the external oil adjustment is set to the appropriate rate for the downstream flow.
• Drain and inspect the filter bowl on a scheduled maintenance interval. Verify automatic drain function at each inspection.
• Replace the filter element on a scheduled interval or when elevated differential pressure is observed.

Warranty & Global Support

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

Technical support is available through ROSS Controls USA at (800) 438-7677 or by visiting rosscontrols.com.

Global support is available through ROSS offices in the USA (Ferndale, Michigan headquarters), Canada, Brazil, Germany, France, United Kingdom, India, China, and Japan.

Contact ROSS Controls at (800) 438-7677 or visit rosscontrols.com for product configuration, replacement parts, and distributor referral.

Download Catalog: https://www.rosscontrols.com/en/documents