Boss Infinity Operator, Maintenance And Parts Manual
BOSS MODEL INFINITY
PTO AIR COMPRESSOR
OPERATORS, MAINTENANCE
AND PARTS MANUAL
P/N: 307200
06/05/2008 MCM
OPERATORS, MAINTENANCE, AND PARTS MANUAL
BOSS INDUSTRIES INFINITY
Operation & Maintenance Section
TABLE OF CONTENTS
Operation & Maintenance Section
Specifications...................................................................................................................... 6
Safety .................................................................................................................................. 7
Compressor T erminology .................................................................................................. 11
Description of Components............................................................................................... 12
Inspection, Lubrication, and Maintenance.......................................................................... 16
Troubleshooting................................................................................................................. 24
Compressor Operation ...................................................................................................... 27
Parts and Illustration Section ............................................................................................. 29
Recommended Spare Parts ................................................................................................ 36
Service Questionnaire........................................................................................................ 37
Instructional Procedures for Installation ........................................................................... 38
Warranty Section
W arranty Information ........................................................................................................ 43
4
SPECIFICATIONS
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SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE
8
D D
7
Parts List
COMPR MTG SYS, INFINITY 45-60-150 SCI8G 0820035311
ELEC SYS, INFINITY 45-60-150 SCI8G 08200355-999 12
OIL-AIR-HYD CLNG SYS, INFINITY SCI8G 08200356-999 13
CANOPY SYS, INFINITY 45-60-150 SCI8G 0820035414
DESCRIPTIONPART NUMBERQTYITEM
6
5
4
3
2
1
C C
34 3/4 in
[882.7 mm]
B B
6 3/8 in
[163.2 mm]
17 3/4 in
[450.9 mm]
5 in
[127.0 mm]
DIMENSIONS OF MOUNTING HOLES
32 1/4 in
[819.2 mm]
A A
8
7
6
19 in
[481.4 mm]
20 1/4 in
[514.4 mm]
PROPRIETARY INFORMATION
THIS DRAWING AND ALL ITS
CONTENTS ARE PROPERTY
OF BOSS INDUSTRIES, INC.
AND MUST NOT BE COPIED
OR MADE PUBLIC. IT IS
LOANED AND IS SUBJEC T TO
RETURN UPON DEMAND. THE
INFORMATION CONTAINED IN
THIS DRAWING IS
CONFIDENTIAL AND MU ST
REV DESCRIPTION DATE ENG
1
5
4
REVISION HISTORY
UPDATED 200353 TO REV 1, 200354 TO REV 1
3
5/22/2008 MCM
NOT BE USED, DIRECTLY OR
INDIRECTLY, IN ANY WAY
DETRIMENTAL TO THE
INTEREST OF BOSS
INDUSTRIES, INC.
UNMACHINED SURFACES
MACHINED SURFACES
NOMINAL DIM.
FRACTIONAL ` 1/16
`
.010
0.000 TO 1.000
`
.03
DECIMAL
`
.015
1.001 TO 5.000
`
1°
ANGULAR
`
.020
5.001 TO 10.000
DO NOT SCALE
TOLERANCES
`
.025
10.001 & OVER
UNLESS NOTED
DRAWN
12/3/2007
DCL
CHECKED
12/3/2007
NDD
MATERIAL
N/A
PATH
G:\Inventor Files\20k\20054-001.dwg
2
DESCRIPTION
INFINITY 45-60 SCI8G 08
SIZE
DWG NO
SCALE
1=4
20054-001
D
R
BOSS INDUSTRI ES
1761 GENESIS DR.
LA PORTE, IN 46350
SHEET
1
REV
1
1 1
OF
6
SAFETY
WARNING
ALL UNITS ARE SHIPPED WITH A DET AILED OPERA TORS AND P ARTS
MANUAL. THIS MANUAL CONT AINS VITA L INFORMA TION FOR THE SAFE
USE AND EFFICIENT OPERA TION OF THIS UNIT . CAREFULLY READ
THE OPERAT ORS MANUAL BEFORE ST ARTING THE UNIT . F AILURE T O
ADHERE TO THE INSTRUCTIONS COULD RESULT IN SERIOUS BODILY
INJURY OR PROPERTY DAMAGE.
AIR COMPRESSOR SAFETY PRECAUTIONS
Safety is basically common sense. While there are standard safety rules, each situation has its own
peculiarities that cannot always be covered by rules. Therefore with your experience and common
sense, you are in a position to ensure your safety . Lack of attention to safety can result in:
accidents, personal injury , reduction of efficiency and worst of all - Loss of Life. W atch for safety
hazards. Correct them promptly . Use the following safety precautions as a general guide to safe
operation:
Do not attempt to remove any compressor parts without first relieving the entire system of
pressure.
Do not attempt to service any part while machine is operating.
DANGER
CHECK THE COMPRESSOR SUMP OIL LEVEL ONL Y WHEN THE COMPRESSOR
IS NOT OPERA TING AND SYSTEM IS COMPLETEL Y RELIEVED OF PRESSURE.
OPEN SERVICE VAL VE TO ENSURE RELIEF OF SYSTEM AIR PRESSURE WHEN
PERFORMING MAINTENANCE ON COMPRESSOR AIR/OIL SYSTEM. FAILURE
TO COMPL Y WITH THIS W ARNING MA Y CAUSE DAMAGE TO PROPERTY
AND SERIOUS BODIL Y HARM.
Do not operate the compressor at pressure(s) or speed in excess of its rating as indicated in
“Compressor Specifications”.
Periodically check all safety devices for proper operation.
Do not play with compressed air . Pressurized air can cause serious injury to personnel.
Exercise cleanliness during maintenance and when making repairs by covering parts and exposed
openings.
7
SAFETY
Do not install a shut-off valve between the compressor and compressor oil sump.
DANGER
DO NOT USE BOSS INDUSTRIES COMPRESSOR SYSTEMS TO PROVIDE
BREA THING AIR. SUCH USAGE, WHETHER SUPPLIED IMMEDIA TELY FROM
THE COMPRESSOR SOURCE, OR SUPPLIED TO BREATHING TANKS FOR
SUBSEQUENT USE, CAN CAUSE SERIOUS BODIL Y INJURY.
BOSS INDUSTRIES, INC. DISCLAIMS ANY AND ALL LIABILITIES FOR DAMAGE
FOR LOSS DUE TO PERSONAL INJURIES, INCLUDING DEATH, AND/OR
PROPERTY DAMAGE INCLUDING CONSEQUENTIAL DAMAGES ARISING OUT
OF ANY BOSS INDUSTRIES, INC. COMPRESSORS USED T O SUPPL Y BREA THING
AIR.
Do not disconnect or bypass safety circuit system.
Do not install safety devices other than authorized BOSS INDUSTRIES, INC. replacement
devices.
Close all openings and replace all covers and guards before operating compressor unit.
T ools, rags, or loose parts must not be left on the compressor or drive parts.
Do not use flammable solvents for cleaning parts. This can cause the unit to ignite during operation.
Keep combustibles out of and away from the Compressor/Inlet and any associated enclosures.
The owner, lessor , or operator of the Compressor are hereby notified and forewarned that any
failure to observe these safety precautions may result in damage or injury .
BOSS INDUSTRIES, INC. expressly disclaims responsibility or liability for any injury or damage
caused by failure to observe these specified precautions or by failure to exercise that ordinary
caution and due care required when operating or handling the Compressor, even though not
expressly specified above.
8
SAFETY
A compliment of warning decals is supplied with each unit. These decals must be affixed to the
comressor package in the locations noted in this manual. If for any reason a safety decal is
removed it is the owners responsibility to make sure it is replaced.
9
SAFETY
10
COMPRESSOR TERMINOLOGY
AIR/OIL COALESCER - Performs second stage separation of oil from compressed air feeding
air tools. Sometimes referred to as the separator element.
CFM - Refers to the volume of compressed air being produced, expressed as cubic feet of air per
minute.
COMPRESSOR LUBRICANT - DEXTRON III ATF.
GPM - Refers to the amount of gallons per minute of hydraulic fluid flowing through the pump.
OIL SUMP - The first stage of oil separation from compressed air . Also serves as reservoir area
for compressor lubricant and sometimes referred to as the receiver tank.
PSI - Refers to the operating pressure the system is set up at, expressed as pounds per square
inch.
SAFETY VALVE - A valve located on the oil sump which opens in case of excessive pressure.
Sometimes referred to as the pop-off or pressure relief valve.
11
DESCRIPTION OF COMPONENTS
COMPRESSOR ASSEMBL Y
The BOSS INDUSTRIES hydraulic drive compressor assembly is a positive displacement, oil
flooded, rotary screw type unit employing one stage of compression to achieve the desired
pressure. Components include a housing (stator), two screws (rotors), bearings, and bearing
supports. Power from the hydraulic motor shaft is transferred to the male rotor through a drive
coupling. The female rotor is driven by the male rotor . There are five lobes on the male rotor
while the female rotor has six roots.
PRINCIPLES OF OPERA TION
In operation, two helical grooved rotors mesh to compress air. Inlet air is trapped as the male
lobes roll down the female grooves, pushing trapped air along, compressing it until it reaches the
discharge port in the end of the stator and delivers smooth-flowing, pulse-free air to the receiver .
During the compression cycle, oil is injected into the compressor and serves these purposes:
1. Lubricates the rotating parts and bearings.
2. Serves as a cooling agent for the compressed air .
3. Seals the running clearances.
LUBRICATION SYSTEM
Oil from the compressor at discharge pressure, is directed into its integral housing, through the
thermal valve and filter, and then out of the integral housing to the oil cooling system, and then back
to the side of the compressor stator, where it is injected into the compressor . At the same time oil
is directed internally to the bearings and shaft seal of the compressor.
OIL SUMP
Compressed, oil-laden air enters the sump from the compressor. As the oil-laden air enters the
sump, most of the oil is separated from the air as it passes through a series of baffles and diffusion
plates. The oil accumulates at the bottom of the sump for recirculation. However , some small
droplets of oil remain suspended in the air and are passed on to the Coalescer .
12
DESCRIPTION OF COMPONENTS
SAFETY V ALVE
The pop safety valve is set at 200 PSI and is located at the top of the air/oil sump. This valve acts
as a backup to protect the system from excessive pressure that might result from a malfunction.
AIR/OIL COALESCER
The coalescer is self-contained within a spin-on housing. When air is demanded at the service line,
it passes through the coalescer which efficiently provides the final stage of oil separation.
OIL RETURN LINE
The oil that is removed by the coalescer accumulates and is returned through an internal oil return
line leading to the compressor .
MINIMUM PRESSURE VAL VE
The minimum pressure valve is located at the outlet of the coalescer head and serves to maintain a
minimum discharge pressure of 75 PSIG in operation, which is required to assure adequate
compressor lubrication pressure.
OIL FIL TER
The compressor oil filter is a removable and cleanable screen built into the side of the compressor
housing. Screen replacement may be necessary after several cleanings.
COMPRESSOR OIL AND HYDRAULIC OIL COOLING SYSTEMS
The compressor cooling system consists of a combination hydraulic cooler and compressor cooler
mounted on the common frame. Compressor oil temperature is controlled by a thermal valve
located down stream of the oil filter . The thermal valve maintains the compressor oil temperature
at 185ºF . Cool air is drawn through the vented end panel and across the combo cooler . The air is
heated by the coolers and the hot air exits out the back vented panel . Allow for adequate
clearance (12”) for the air to exit. Also, the package location should not be subjected to above
ambient air temperatures.
13
DESCRIPTION OF COMPONENTS
INSTRUMENTATION
The BOSS INDUSTRIES hydraulic drive compressor unit incorporates a gauge panel that monitors
temperature, pressure and hours of operation.
HOURMETER
The hourmeter records the total number of operating hours. It serves as a guide in following the
recommended inspection and maintenance schedule. The hourmeter will only run when there is pressure
in the system.
COMPRESSOR DISCHARGE AIR/OIL TEMPERATURE SWITCHGAUGE
This switchgauge indicates compressor air discharge temperature. The switchgauge ensures safety
shutdown in case of excessive operating temperatures, preventing compressor damage, by stopping
hydraulic flow to the compressor motor.
ELECTRICAL AND SAFETY SYSTEM
The BOSS INDUSTRIES compressor’s standard electrical system consists of:
-Gauge panel with a temperature switchgauge, hourmeter and discharge pressure switchgauge.
-Compressor and hydraulic oil cooler fan assembly and relay .
-Compressor after cooler/oil cooler fan assembly and relay .
-3-way pressure switch and relay to control hourmeter and blowdown.
-12VDC N.O. hydraulic solenoid and relay .
-Switch relay for customer equipment interface during compressor operation.
-Differential pressure switch for air filter maintenance.
-Optical oil level switch and relay .
14
DESCRIPTION OF COMPONENTS
CONTROL SYSTEM
The prime component of the compressor control system is the compressor inlet valve. The control
system is designed to match air supply to air demand and to prevent excessive discharge pressure
when compressor is at idle. Control of air delivery is accomplished by the inlet valve regulation
and modulation as directed by the discharge pressure regulator .
NORMALL Y OPEN REGULATOR SOLENOID
A closed Furnas air pressure switch will energize the normally open regulator solenoid, thus closing
it. When the normally open regulator solenoid is closed, air pressure will rise. When it is open air
pressure falls only in the compressor sump.
NOTE: Most air tools operating pressure range is between 90 and 125 psi. Operating
above the tools recommended pressures will decrease the life of the tool. Higher
operating pressure can also over torque nuts and bolts fatiguing the fastener and mating
parts. Strictly adhere to tool operating pressures and torque standards set forth by the
tool manufacturer and the specifications of the equipment that work is being performed
on.
FURNAS SWITCH DESCRIPTION
The Furnas switch is a N.C. electrical switch set to open at 150 PSI and set to close at 115 PSI.
The Furnas switch controls the N.O. regulator solenoid. If service air pressure is under 150 PSI,
the Furnas switch will not trip keeping the N.O. inlet valve open and the compressor making air. If
the service valve is closed or the tool using the air is off, service line pressure will rise over 150
PSI. This will trip the Furnas switch to open. The regulator solenoid will open and send air
pressure to the inlet valve to close. W ith the inlet valve closed, the compressor will stop making
air. If the tool is turned on or the service valve is opened, the service line pressure will drop.
When the pressure falls to 115 PSI the Furnas switch will close energizing the N.O. regulator
solenoid closing off the air supply to the inlet valve. This will allow the inlet valve to open, and the
compressor will start making air to meet the demand.
INLET V A LV E
The compressor inlet valve is a piston operated disc valve that regulates the inlet opening to control
capacity and serves as a check valve at shutdown.
15
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