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 is a modular Filter Regulator Lubricator (FRL) combination product line for 1/4" to 3/4" port size compressed air systems. The Full-Size Series delivers combined filtration, pressure regulation, and lubrication with flow capacity up to 138 scfm (3906 l/min), making it the appropriate selection for main machine air preparation in larger industrial pneumatic systems with 1/2" and 3/4" supply circuits.

The Full-Size Series FRL components are offered individually as a filter, a diaphragm-type regulator, and a sight-feed lubricator, and are designed for modular mounting to form a compact side-by-side FRL station. The modular design accommodates filter-only, filter/regulator, and complete filter/regulator/lubricator configurations to match the air treatment requirements of each application.

The filter unit is available with a polycarbonate plastic bowl with steel shatterguard or a zinc metal bowl with a clear nylon sight glass. Filter drain options include internal automatic drain, manual drain, and electronic drain for applications requiring timed or demand-triggered condensate management. The diaphragm-type regulator provides high-sensitivity pressure regulation with stable output pressure across the full flow range. The sight-feed lubricator delivers visible, adjustable oil injection into the compressed air stream for downstream actuator and tool lubrication.

The Full-Size Series addresses the air preparation needs of larger industrial machines, assembly line main air supplies, and multi-actuator pneumatic systems where 3/4" port size and flow capacity above 100 scfm are required from a modular FRL assembly.

Key Engineering Features

• Full-Size Flow Capacity with Modular Assembly - Delivers up to 138 scfm (3906 l/min) at port sizes up to 3/4", providing the flow capacity required for full-size industrial machine air preparation while retaining the modular assembly advantages of individual component selection.
• Extended Port Size Range to 3/4" - Port sizes from 1/4" to 3/4" enable the Full-Size Series to serve as the main air preparation station for machines and systems with 1/2" and 3/4" compressed air supply inlets.
• Polycarbonate Bowl with Steel Shatterguard or Zinc Bowl with Sight Glass - Polycarbonate bowl with steel shatterguard combines visual condensate monitoring with impact protection; zinc metal bowl with clear nylon sight glass provides metal construction with retained visual condensate level access.
• Three Drain Options Including Electronic - Internal automatic drain, manual drain, and electronic drain options provide complete flexibility in condensate management, with the electronic drain minimizing compressed air loss through demand-based or timed drain cycling.
• Diaphragm-Type Regulator - Self-relieving diaphragm-type regulator provides high sensitivity and low droop pressure control, maintaining stable regulated output pressure across the variable flow demand of large industrial pneumatic circuits.
• Non-Relieving Regulator Option - Non-relieving regulator option available for applications where venting excess downstream pressure to atmosphere is not permitted.
• Sight-Feed Lubricator - Sight-feed oil delivery provides visible confirmation of lubrication rate, allowing operators to verify and adjust oil delivery at the FRL station during system commissioning and maintenance.
• Integral Pressure Gauge - Pressure gauge is included as standard on regulator units for continuous output pressure monitoring at the FRL station.
• Customized Air Treatment Combination - Individual component availability allows the Full-Size Series to be ordered as a filter only, filter/regulator combination, or complete FRL without purchasing unneeded components.

Technical Specifications

General Specifications

Certifications & Compliance

Typical Applications & Industries

Large Industrial Machine Air Preparation

• Main machine air preparation for large industrial automation cells, press lines, and processing equipment with 3/4" supply circuits requiring FRL flow capacity at or above 100 scfm for full machine demand.
• Manufacturing line main air inlet FRL stations serving multiple downstream solenoid valve manifolds, pneumatic actuators, and tool circuits requiring filtered, regulated, and lubricated supply from a single 3/4" FRL station.
• Centralized air preparation for machine tool centers, transfer lines, and flexible manufacturing systems where the Full-Size Series FRL provides the air treatment gateway for all downstream pneumatic components.
• Industrial conveyor systems with high flow demand from multiple actuators, pneumatic brakes, and friction clutch-brake units requiring a high-flow FRL combination at the main air supply inlet.

Automotive and Heavy Manufacturing

• Automotive body shop main air preparation for welding robot pneumatic circuits, fixture clamping, and material handling with 3/4" supply ports requiring the full-size flow capacity of the series FRL.
• Stamping and forming press pneumatic circuits with die cushion, material feed, and scrap handling systems requiring filtered and regulated supply from a full-size FRL at the press air supply inlet.
• Final assembly line air preparation stations serving banks of pneumatic tools, torque tools, and assembly actuators from a common 3/4" FRL station providing filtered, regulated, and lubricated air.
• Heavy equipment manufacturing with large pneumatic actuators, riveting guns, and assembly fixtures requiring high-flow air preparation from a Full-Size Series FRL combination.

Packaging and Distribution Equipment

• High-speed case packing, palletizing, and stretch wrapping equipment with 1/2" to 3/4" main air supply circuits requiring full-size FRL flow capacity during simultaneous actuator operation.
• Distribution center conveyor and sortation systems with pneumatic diverters, pop-up transfers, and air-blast label application stations served by Full-Size Series FRL combinations at major pneumatic zone inlets.
• Industrial packaging line main air preparation for fill and seal, cartoning, and secondary packaging machines requiring 100 to 138 scfm of filtered, regulated, and lubricated air.
• Automated warehouse systems with pneumatic actuated gate valves, transfer tables, and product handling requiring high-flow air preparation from modular Full-Size Series FRL stations.

Process Industry and Utilities

• Compressed air utility distribution headers in chemical, petrochemical, and industrial process plants where Full-Size Series FRL stations provide filtered and regulated instrument air to control valve and actuator sub-headers.
• Water and wastewater treatment pneumatic actuated valve supply systems with 3/4" instrument air supply circuits requiring full-size FRL flow capacity for multiple valve actuators served from a common FRL station.
• Power generation facility pneumatic control circuits for combustion air dampers, lube oil systems, and turbine controls requiring filtered, regulated instrument air from full-size FRL combinations.
• Oil and gas plant pneumatic actuator supply systems requiring reliable air preparation with electronic drain management to minimize compressed air waste in remote or unmanned installations.

Food and Beverage Processing

• Large food processing lines with 3/4" pneumatic circuits serving multiple conveying, weighing, and packaging actuators requiring full-size FRL flow capacity at the line main air preparation station.
• Beverage plant pneumatic distribution systems with bottle and can handling, filling carousel actuators, and CIP valve manifolds served by Full-Size Series FRL stations at each functional zone.
• Commercial bakery and large-scale food production equipment with high-flow pneumatic circuits for product handling, forming, and packaging requiring filtered, regulated, and lubricated air from a 3/4" FRL station.

Woodworking and Building Products

• Wide-belt sanding machines, CNC machining centers, and panel processing equipment with 3/4" supply circuits requiring Full-Size Series FRL capacity at the machine main air inlet.
• Window and door manufacturing lines with pneumatic glass handling, frame assembly, and hardware installation circuits requiring high-flow filtered and regulated air from a central FRL station.
• Engineered wood products manufacturing with pneumatic press systems, material handling conveyors, and adhesive application equipment served by Full-Size Series FRL combinations.

Ordering and Model Number Configuration

The Full-Size Series FRL components are ordered individually as filter, regulator, or lubricator units and assembled into modular combinations. Specify port size, bowl material, drain type, and regulator function. Contact ROSS Controls at (800) 438-7677 or visit rosscontrols.com for complete ordering information.

Port sizes available: 1/4", 3/8", 1/2", and 3/4" NPT.

Filter bowl material: polycarbonate with steel shatterguard (150 psig maximum), or zinc metal with clear nylon sight glass (200 psig maximum).

Drain options: internal automatic drain, manual drain, or electronic drain. Electronic drain is recommended for high-flow applications requiring condensate management without continuous air loss.

Regulator type: diaphragm-type. Self-relieving (standard) or non-relieving option.

Lubricator type: sight-feed for visible oil delivery monitoring.

For complete catalog part numbers, dimensional drawings, and modular assembly configurations, visit rosscontrols.com or contact ROSS Controls technical sales.

Accessories

Modular Mounting Brackets and Hardware

Full-Size Series modular bracket systems interconnect filter, regulator, and lubricator units into a compact side-by-side assembly for panel, wall, or pipe mounting.

Electronic Drain Controllers

Timer-based and demand-sensing electronic drain controllers for use with Full-Size Series filter units equipped with electronic drain connections.

Replacement Filter Elements

Replacement filter elements for the Full-Size Series filter units in 5-micron and 40-micron particulate removal grades.

Pressure Gauges

Replacement and additional pressure gauges for Full-Size Series regulator units in various dial sizes and pressure ranges.

Related Products & Accessories

• MD3 Series FRL Combination - High-flow modular FRL combination for 1/4" to 1/2" port sizes with flow to 110 scfm (3115 l/min). https://www.rosscontrols.com/en/series/148-md3-series
• MD4 Series FRL Combination - Higher-flow modular FRL combination for 3/8" to 3/4" port sizes with flow to 205 scfm (5806 l/min). https://www.rosscontrols.com/en/series/150-md4-series
• 70 Full-Size Series Filter - Individual full-size filter component for 1/4" to 3/4" port sizes, flow to 155 scfm (4490 l/min). https://www.rosscontrols.com/en/series/70-full-size-series
• 151 High Capacity FRL Combination - High-capacity inline FRL combination for 3/4" to 1-1/2" port sizes with flow to 495 scfm (14018 l/min). https://www.rosscontrols.com/en/series/151-high-capacity
• Flow Controls - ROSS flow control valves for pneumatic actuator speed regulation downstream of FRL assemblies. https://www.rosscontrols.com/en/series/261-flow-controls

Frequently Asked Questions (FAQ)

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

A: The Full-Size Series FRL combination delivers maximum flow of 138 scfm (3906 l/min) at port sizes from 1/4" to 3/4".

Q: What port sizes are available?

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

Q: What is the difference between the Full-Size Series and the MD3 Series (148)?

A: The Full-Size Series extends the port size range to 3/4" and provides flow up to 138 scfm compared to 1/2" and 110 scfm for the MD3. The Full-Size Series uses a sight-feed lubricator versus a standard lubricator in the MD3. Both series use modular mounting and offer electronic drain options.

Q: When should I select the zinc metal bowl versus the polycarbonate bowl with shatterguard?

A: Select the zinc metal bowl with sight glass when operating pressure exceeds 150 psig (requiring the 200 psig-rated metal bowl), ambient temperature exceeds 125 degrees F, or the installation environment involves mechanical impact hazards where a fully metal bowl construction is required. Select the polycarbonate bowl with shatterguard when visual condensate level monitoring is needed and operating conditions are within the 150 psig and 125 degrees F envelope.

Q: What is the advantage of a sight-feed lubricator versus a wick-feed lubricator?

A: A sight-feed lubricator provides a visible window or drop tube where oil dripping into the air stream can be directly observed, allowing the operator to confirm that lubrication is occurring and to monitor the delivery rate during operation. Wick-feed lubricators do not provide direct visual confirmation of delivery rate. Sight-feed models are preferred on large systems where confirming lubricator function during normal operation is important for maintenance.

Q: What is the electronic drain and when should it be specified?

A: The electronic drain uses a solenoid valve actuated by a timer or condensate level sensor to expel condensate at programmed intervals or on demand rather than continuously. Electronic drains are specified for high-flow applications where continuous automatic float drains would waste significant compressed air, for remote or unattended installations where manual drain servicing is impractical, and for applications with intermittent condensate generation where a float drain may remain open during low-condensate periods.

Q: Can the Full-Size Series components be ordered individually?

A: Yes. The filter, regulator, and lubricator are each available as individual components. They can be combined into any two-unit or three-unit modular FRL assembly using Full-Size Series modular hardware.

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

A: The Full-Size Series uses a diaphragm-type regulator. Self-relieving is standard; non-relieving is available as an option.

Q: What is the maximum operating pressure?

A: Maximum operating pressure is 150 psig (10 bar) with polycarbonate bowls and 200 psig (14 bar) with zinc metal bowls.

Q: What temperature range is the Full-Size Series rated for?

A: Polycarbonate bowl units are rated for 40 to 125 degrees F (4 to 52 degrees C). Zinc metal bowl units are rated for 40 to 150 degrees F (4 to 66 degrees C).

Q: What mounting orientation is required?

A: Mount with the filter and lubricator bowls in the downward (vertical) position to allow condensate to collect at the drain and oil to be accessible at the lubricator fill port.

Q: How do I select the correct filtration grade?

A: For general machine air preparation supplying pneumatic cylinders and actuators, a 5-micron particulate filter element is the standard selection. Use a 40-micron element for pre-filtration upstream of a finer filter stage or for low-contamination supply systems. Coalescing filter elements are available for applications requiring oil aerosol and particulate removal.

Q: Where can I find catalog part numbers and drawings?

A: Complete catalog part numbers, dimensional drawings, and technical data are available at rosscontrols.com. Contact ROSS Controls at (800) 438-7677 for configuration assistance.

Installation & Maintenance Guidelines

• Mount the Full-Size Series FRL assembly with the bowls in the downward (vertical) position to allow condensate to collect at the drain and to maintain lubricator bowl orientation for proper oil level.
• Install components in the correct flow sequence: filter (inlet) - regulator (middle) - lubricator (outlet), ensuring air is filtered before regulation and lubricated after pressure regulation.
• Verify that the flow direction arrow on each unit body is aligned with the compressed air flow direction before making port connections.
• Apply thread sealant to all NPT port connections and tighten to the torque specified in the ROSS Controls installation instructions. Over-tightening can damage port threads or the body.
• Pressurize the system gradually after installation and check all connections and bowl seals for air leakage with an approved leak detection solution.
• Set regulated output pressure by unlocking the regulator adjustment knob, rotating to the target pressure reading on the gauge, and locking the knob at the set point.
• Fill the lubricator bowl with petroleum-based oil of ISO 32 or lighter viscosity to the maximum fill level. Adjust the oil delivery rate using the needle valve while observing the sight glass.
• For electronic drain models, configure the drain timer or demand control per the condensate volume and application requirements.
• Verify that automatic drain models expel condensate properly during normal operation. For manual drain models, establish a scheduled draining interval appropriate to the condensate volume.
• Connect a pressure gauge to both the inlet and outlet gauge ports on the regulator if differential pressure monitoring is required for the application.
• Replace filter elements at the differential pressure service threshold or at the scheduled maintenance interval. Always depressurize and isolate the assembly before removing the bowl.
• Inspect the lubricator oil level regularly. Refill with the specified lubricant before the oil level reaches the minimum mark on the bowl sight glass.

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 and product configuration assistance is available through ROSS Controls at (800) 438-7677 or 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.

For complete technical data, dimensional drawings, and ordering information for the Full-Size Series FRL combination, visit rosscontrols.com or contact ROSS Controls technical sales.