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 high-capacity line of modular and inline lubricators designed for pneumatic systems operating on 1/4, 3/8, 1/2, and 3/4 inch port sizes at flow rates up to 140 scfm (3,965 l/min). As the widest port range offering in the ROSS standard lubricator lineup, the Full-Size Series supports the broadest spectrum of industrial pneumatic circuits from small quarter-inch instrumentation feeds to large three-quarter inch main headers.

A distinguishing characteristic of the Full-Size Series is the availability of both sight-feed and wick-feed lubrication designs within the same product family. Sight-feed models provide visible oil drop monitoring through a nylon sight dome, enabling operators to confirm active lubrication during production. Wick-feed models deliver continuous, low-pulsation oil introduction that is better suited for systems requiring ultra-consistent lubrication at flow rates below or above the sight-feed mechanism's drop delivery range.

The external adjusting knob on Full-Size Series models is designed to be removable. With the knob removed, the current oil delivery rate setting is maintained without an exposed adjustment interface, providing tamper-resistant protection against inadvertent setting changes. For wick-feed models, a separate wick-feed internal adjustment is provided for non-visual delivery calibration.

The Full-Size Series uses an 8-oz (240-ml) bowl, providing nearly double the reservoir capacity of the smaller mid-size and MD3 series, reducing oil refill frequency for high-consumption applications. Bowl choices include polycarbonate with steel shatterguard (standard) and zinc with nylon sight glass (metal option). The acetal adjusting knob and aluminum bowl ring complete the construction for a robust, long-service lubricator assembly.

Key Engineering Features

• Sight-Feed or Wick-Feed Design Selection - Choose sight-feed for visual oil drop monitoring during production, or wick-feed for continuous oil delivery with internal adjustment in applications where sight monitoring is not required. Both designs are available in all port sizes.
• Modular or Inline Mounting - Mounts in a complete modular FRL assembly with ROSS Full-Size Series filters and regulators, or as a standalone inline lubricator in an existing pipeline. Flexible configuration for new system design or retrofit installation.
• External Removable Adjusting Knob - Acetal external adjusting knob controls oil delivery rate and can be physically removed from the lubricator body. Removing the knob locks the current setting and eliminates the adjustment interface, providing a robust tamper-resistant configuration.
• Widest Port Size Range in Standard Series - Available in 1/4, 3/8, 1/2, and 3/4 inch port sizes with both NPTF and G (BSPP) threads, covering small instrumentation circuits through large pneumatic supply headers in a single product family.
• 8-oz (240-ml) Bowl Capacity - Larger reservoir volume compared to Bantam (2 oz), Miniature (2 oz), and Mid-Size (4 oz) series lubricators reduces oil refill frequency for higher-consumption circuits. Accommodates longer production runs between maintenance intervals.
• Polycarbonate with Steel Shatterguard or Zinc Bowl - Polycarbonate bowl with steel shatterguard for standard applications to 150 psig (10 bar) and 125 F (52 C). Zinc metal bowl with nylon sight glass extends pressure to 200 psig (14 bar) and temperature to 175 F (80 C).
• Quick-Fill Cap Option - Optional quick-fill cap available for all Full-Size Series models. Allows pressurized oil refilling without removing the bowl, reducing maintenance time on high-availability production lines.
• Zinc Body with Aluminum Bowl Ring - Zinc die-cast body provides structural integrity for industrial service. Aluminum bowl ring provides a durable interface between body and bowl for repeated removal and reinstallation during maintenance cycles.

Technical Specifications

General Specifications

Certifications & Compliance

Typical Applications & Industries

Large Pneumatic Actuator Systems

• Pneumatic cylinder banks supplying 100 mm to 200 mm bore actuators in automotive transfer line clamping fixtures, where 3/4 inch supply headers at 100 to 140 scfm require Full-Size lubricator capacity to lubricate multiple large-bore cylinders simultaneously.
• Double-acting pneumatic press cylinders in metal stamping and forming operations, where sight-feed monitoring through the nylon dome confirms active lubrication during full-production-speed cycling.
• Large pneumatic cylinder circuits in paper mill and printing press infrastructure, where 3/4 inch headers supply press section pneumatic controls and the zinc bowl option handles the elevated ambient temperatures near press dryer sections.

Pneumatic Power Tools - High Volume Distribution

• Pneumatic tool supply headers in foundry, shipyard, and heavy maintenance facilities where multiple operators draw from 3/4 inch air drops supplying grinders, chippers, and impact tools at simultaneous flow rates requiring lubricator capacity above 100 scfm.
• Compressed air distribution systems in aircraft MRO hangars, where tool supply drops in 3/8 and 1/2 inch sizes are served by point-of-use Full-Size FRL stations providing clean, regulated, lubricated air at each workstation.
• Automotive body shop pneumatic tool distribution, where assembly line drops supply ratchets, impact drivers, and grinders and the wick-feed Full-Size lubricator provides continuous oil delivery without the visual monitoring overhead of sight-feed designs.

Process Industry Pneumatic Actuators

• Process control valve pneumatic actuators in chemical plants and refineries, where 1/2 and 3/4 inch supply lines at elevated pressures up to 200 psig require the zinc bowl Full-Size lubricator rated for those conditions.
• Diaphragm pump drive pneumatic circuits in process chemical transfer applications, where consistent wick-feed lubrication maintains diaphragm actuator seal and spring integrity across continuous 24-hour operation.
• Pneumatic block and bleed valve actuators on pipeline equipment, where zinc bowl models support the higher operating pressures common in upstream oil and gas pneumatic service.

Pulp, Paper, and Printing

• Newsprint and coated paper web press pneumatic cylinder circuits, where 3/4 inch supply lines at high flow rates feed dancer roll actuators, tension roll positioners, and web guide actuators requiring continuous lubrication.
• Flexographic printing press pneumatic registration and impression cylinder controls, where sight-feed monitoring in the Full-Size lubricator provides visual confirmation of active lubrication during press makeready and production runs.
• Paper coating line pneumatic actuators for blade, metering rod, and roll nip control, where the 8-oz bowl provides extended service intervals matched to coating line maintenance schedules.

Agriculture and Food Processing Equipment

• Grain elevator pneumatic valve actuators and conveyor diverters, where 3/4 inch supply circuits in grain handling environments benefit from zinc bowl construction that resists dust, grain chaff, and periodic cleaning chemical exposure.
• Pneumatic actuators on food processing filling lines and depositor equipment in secondary packaging zones, where polycarbonate bowl transparency supports quick visual checks during production and the full-size capacity handles multiple actuators from a single lubricator.
• Dairy equipment pneumatic control actuators for pasteurizer valve panels, where the Full-Size sight-feed model in a 1/2 inch inline configuration integrates into existing pipe circuits without requiring a complete modular FRL station.

Water and Wastewater Treatment

• Pneumatic valve actuators in water treatment plant filter backwash systems, where 3/4 inch supply lines at high flow rates require full-size lubricator capacity and zinc bowls provide corrosion resistance in humid treatment plant environments.
• Sludge handling pneumatic diaphragm pump actuators at wastewater treatment facilities, where consistent wick-feed lubrication extends pump actuator life in continuous service against corrosive process media.
• Pneumatic slide gate and plug valve actuators at pump stations, where outdoor installations benefit from zinc bowl models that tolerate a wider temperature range and resist UV and environmental degradation.

Ordering and Model Number Configuration

Select design type (sight-feed or wick-feed), port size, thread type, bowl material, and fill method. Sight-feed and wick-feed are separate model families with different internal mechanisms.

Sight-feed and wick-feed are separate model numbers and cannot be field-converted between designs.

NPT models have no prefix. G (BSPP) thread models are prefixed with C (e.g., C5111B5008 for 3/4 G, sight-feed, polycarbonate, fill port).

Polycarbonate bowl (5111B) rated to 150 psig (10 bar), 125 F (52 C). Zinc bowl (5112B) rated to 200 psig (14 bar), 175 F (80 C).

Accessories

Full-Size Series Filters

ROSS Full-Size Series filters with 5-micron or 40-micron polyethylene elements for 1/4 to 3/4 inch ports. Available with polycarbonate or zinc bowls, automatic or manual drain. Optional differential pressure gauge.

Full-Size Series Regulators

Modular piston-type and diaphragm-type regulators for 1/4 to 3/4 inch ports. Adjustable pressure up to 125 psig (9 bar) outlet. Available in self-relieving and non-relieving configurations. Optional lockout valve.

Related Products & Accessories

• MD3 Series Lubricators - Modular sight-feed lubricators for 1/4 to 1/2 inch ports with transparent dome and removable knob. 150 scfm capacity and 250 psig metal bowl rating. https://www.rosscontrols.com/en/series/107-md3-series
• MD4 Series Lubricators - Modular sight-feed lubricators with transparent dome for 3/8 to 3/4 inch ports. Extended bowl option. Flow to 205 scfm. https://www.rosscontrols.com/en/series/109-md4-series
• 110 High-Capacity Series Lubricators - Inline sight-feed and wick-feed lubricators for 3/4 to 1-1/2 inch ports. Flow to 500 scfm. Multiple bowl size options. https://www.rosscontrols.com/en/series/110-high-capacity-series
• 106 Mid-Size Series Lubricators - Modular sight-feed lubricators for 1/4 to 1/2 inch ports. 4-oz bowl capacity. Flow to 110 scfm. https://www.rosscontrols.com/en/series/106-mid-size-series

Frequently Asked Questions (FAQ)

Q: When should I select sight-feed versus wick-feed design for the Full-Size Series?

A: Select sight-feed when visual confirmation of oil delivery during production is important, such as during commissioning, troubleshooting, or in facilities with preventive maintenance inspection programs. The sight-feed design shows individual oil drops entering the airstream. Select wick-feed when continuous, uninterrupted oil delivery is preferred without requiring visual monitoring, or in applications where the lubricator is installed in a location that is not easily observed during normal operations.

Q: Can I convert a sight-feed Full-Size lubricator to wick-feed in the field?

A: No. Sight-feed and wick-feed models use different internal mechanisms and have different model numbers. They cannot be converted between designs in the field. If the design type needs to change, order the appropriate model number with the correct design type for the application.

Q: What port sizes does the Full-Size Series cover?

A: The Full-Size Series covers 1/4, 3/8, 1/2, and 3/4 inch ports in both NPTF and G (BSPP) thread standards. This is the widest port size range in the ROSS standard lubricator series, extending from small instrument circuits to large supply headers. For port sizes above 3/4 inch, refer to the 110 High-Capacity Series.

Q: What is the bowl removal clearance requirement?

A: Allow a minimum of 3.1 inches (79 mm) of vertical clearance below the bottom of the lubricator body for bowl removal. This clearance allows the 8-oz bowl to swing clear of the aluminum bowl ring for servicing. Verify this space is available in panel or enclosure installations before mounting.

Q: What is the maximum operating pressure for each bowl type?

A: Polycarbonate bowl with steel shatterguard: maximum 150 psig (10 bar) and 125 F (52 C). Zinc metal bowl with nylon sight glass: maximum 200 psig (14 bar) and 175 F (80 C). Select the bowl material appropriate for the system's actual operating pressure and temperature.

Q: What does the steel shatterguard on the polycarbonate bowl do?

A: The steel shatterguard is a metal cage surrounding the polycarbonate bowl. If the polycarbonate bowl fails, cracks, or shatters due to overpressure or physical impact, the steel shatterguard contains the fragments, preventing bowl material or pressurized air from being expelled in an uncontrolled manner. This is a safety feature required by many industrial facility standards for compressed air components.

Q: Is the Full-Size Series appropriate for outdoor or washdown environments?

A: The zinc bowl model provides better environmental resistance for outdoor and industrial washdown environments than polycarbonate bowl models. In outdoor installations, protect the unit from direct weather exposure where possible. For washdown environments, select the zinc bowl and verify that cleaning chemicals are compatible with zinc, nylon, and acetal materials. Consult ROSS technical support for specific chemical compatibility guidance.

Q: How does the quick-fill cap work on the Full-Size Series?

A: The quick-fill cap is a spring-loaded check valve fitting that replaces the standard fill port plug. Insert an oil dispensing nozzle into the check valve to open it; oil flows into the 8-oz reservoir against system pressure. When the nozzle is removed, the check valve seals and system pressure is maintained. This procedure allows oil refilling without stopping the air supply or removing the bowl.

Q: What is the minimum flow rate required for sight-feed oil delivery?

A: The minimum flow for the Full-Size Series is 2 scfm (0.94 l/s) at 100 psig (6.9 bar) inlet. This is the flow at which the pressure differential is sufficient to draw oil through the sight-feed mechanism and into the airstream. In applications with flow rates consistently below this level, consider the 105 Miniature Series low-flow models.

Q: What lubricant type should be used?

A: Use petroleum-based oil with ISO 32 viscosity or lighter and an aniline point between 180 F and 220 F. Standard pneumatic tool oil meeting these criteria is appropriate. Do not use synthetic fluids, phosphate-ester fluids, or additives incompatible with nitrile seals. Using incorrect lubricants will degrade seals and may void the warranty.

Q: Can Full-Size Series lubricators be combined with other ROSS Series components?

A: Full-Size Series lubricators are designed to combine with ROSS Full-Size Series filters and regulators in modular FRL assemblies. Combining with other ROSS series (Mid-Size, MD3, etc.) is not supported in modular configuration due to differing module interface dimensions. For inline installation, any upstream filter and regulator can be used as long as port sizes and thread standards match.

Q: Is there a pressure gauge port on the Full-Size Series lubricator?

A: The Full-Size Series lubricator body does not have an integral pressure gauge port. Pressure gauges are installed on the upstream Full-Size Series regulator, which includes 1/4 inch NPT gauge ports on the front and rear of the regulator body.

Installation & Maintenance Guidelines

• Install the lubricator downstream of the filter and regulator. Lubricating unfiltered air accelerates wick wear and contaminates the oil reservoir.
• Mount with the bowl in the downward vertical position for proper sight dome and wick operation.
• Verify bowl removal clearance of at least 3.1 inches (79 mm) below the lubricator body before mounting in a panel or enclosure.
• For modular FRL assembly, follow ROSS module assembly instructions. Ensure O-ring seals are correctly seated at module interfaces before tightening tie bolts.
• Verify that system pressure does not exceed the bowl rating: 150 psig for polycarbonate, 200 psig for zinc.
• For sight-feed models, observe the sight dome after startup and set the external knob to achieve the target oil drop rate at operating flow conditions. Remove the knob to activate tamper-resistant mode after adjustment is complete.
• For wick-feed models, set the internal adjustment before installation to the recommended wick position for the application flow range.
• Fill the oil reservoir with petroleum-based ISO 32 or lighter lubricant. Do not fill above the maximum fill mark.
• Use the quick-fill cap option for oil additions during production without stopping the air supply.
• Inspect the sight dome periodically for cloudiness or oil deposits that impair visibility. Inspect the shatterguard for physical damage.

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

Contact ROSS Controls USA at (800) 438-7677 or (248) 764-1800, or visit rosscontrols.com for product configuration, technical support, and distributor locator services.

Download Catalog: https://www.rosscontrols.com/en/documents/198/ROSS_FRL_Combination_Units_Filter_Regulator_Lubricator.pdf