This manual must be read carefully before using your Twin Stars, Ltd. Gas Compres-
sor. Store in a safe and convenient location for future reference.
Service and
Maintenance
Manual
20 HP 8G VRUE
Skid Auto Bypass
Gas Compressor
309777-GN
12/3/2013
For technical support:
Phone: (505) 632-9202 (Outside USA)
Fax: (505) 632-2723 (USA)
Website: http://www.twinstars.com
2 309777-GN
3 309777-GN
Manual Change History................................................................................................7
1.1 Revision List....................................................................................................7
Welcome........................................................................................................................8
2.1 General Information..........................................................................................8
2.2 Overview .........................................................................................................8
Safety...................................................................................................................9-13
3.1 General Safety Overview...................................................................................9
3.2 Safety Precautions..........................................................................................10
3.3 Safety and Information Decals..........................................................................12
Specifications..............................................................................................................14
4.1 Specification Sheet.........................................................................................14
Description of Components..............................................................................15-18
5.1 Electric Motor.................................................................................................15
5.2 Drive Coupling...............................................................................................15
5.3 Compressor Gasend.......................................................................................15
5.4 Separator System..........................................................................................15
Separator Tank.........................................................................................15
Separator Element......................................................................................15
5.5 Inlet Scrubber System.....................................................................................16
Inlet Scrubber............................................................................................16
Low Liquid Level Float Switch....................................................................16
High Liquid Level Float Switch...................................................................16
5.6 Inlet Scrubber Pump.......................................................................................16
5.7 Pressure Relief Valves.....................................................................................16
Separator Tank Relief Valve.......................................................................16
Inlet Scrubber Relief Valve.........................................................................16
5.8 Cooling Systems.............................................................................................17
Compressor Oil Cooler...............................................................................17
Compressor Aftercooler.............................................................................17
5.9 Compressor Oil Filter......................................................................................17
5.10 Compressor Oil Thermal Valve......................................................................17
5.11 Compressor Inlet Valve.................................................................................17
5.12 Minimum Pressure Valve...............................................................................17
5.13 Blowdown Valve..........................................................................................17
5.14 Low Suction Bypass.....................................................................................18
Contents
4 309777-GN
Installation..........................................................................................................19-12
6.1 System Installation Overview...........................................................................19
6.2 Placing the Machine........................................................................................19
6.3 Connecting the Gas Inlet Line...........................................................................19
6.4 Connecting the Gas Discharge Line..................................................................20
6.5 Connecting the Inlet Scrubber Pump Discharge Line........................................20
6.6 Connecting the Electrical Lines........................................................................20
6.7 Pre-Startup Inspection ...................................................................................20
6.8 Machine Documentation.................................................................................20
6.9 Check Fluid Levels.........................................................................................21
6.10 Initial Startup Preparation..............................................................................21
6.11 Initial Startup.................................................................................................21
Operation....................................................................................................................22
7.1 Operating.......................................................................................................22
Maintenance........................................................................................................23-29
8.1 Maintenance Overview....................................................................................23
8.2 Maintenance Schedule....................................................................................23
8.3 Recommended Spare Parts List......................................................................24
8.4 Parts and Service Contact Information............................................................24
8.5 Maintenance Log............................................................................................25
8.6 Separator Element Replacement......................................................................26
8.7 Compressor Oil..............................................................................................27
Specifications.......................................................................................28
Adding Compressor Oil.............................................................................28
Changing Compressor Oil..........................................................................28
8.8 Compressor Oil Cooler.................................................................................29
8.9 Compressor Oil Filter....................................................................................29
Troubleshooting...................................................................................................30-31
9.1 Troubleshooting Chart....................................................................................30
9.2 Parts and Service Contact Information............................................................31
Warranty.....................................................................................................................32
10.1 Warranty Policy............................................................................................32
Parts and Illustration Section...........................................................................34-54
11.1 Frame System...............................................................................................34
11.2 Motor System...............................................................................................36
11.3 Compressor System.....................................................................................38
Contents
5 309777-GN
Parts and Illustration Section (continued)........................................................34-54
11.4 Discharge System..........................................................................................40
11.5 Cooler System..........................................................................................42
11.6 Scrubber System..........................................................................................44
11.7 Decal System................................................................................................46
11.8 Canopy System............................................................................................48
11.9 Electrical Water Pump..................................................................................50
11.10 System Wiring Diagram...............................................................................52
11.11 Hose System...............................................................................................53
11.12 Gas/Oil Schematic......................................................................................54
Flow Charts Section....................................................................................................55
12.1 SCG8G Flow Chart......................................................................................55
Contents
6 309777-GN
7 309777-GN
Manual Change History
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1.1 Revision List
8 309777-GN
Welcome
2.2 Overview
The 20 HP VRUE Skid Compressor is a compact, strategically designed system. It integrates all major
components on a single, environmentally sealed frame, which is enclosed in a tough, weather-resistant
canopy.
The 20 HP VRUEs rotary screw design guarantees
continuous gas output, see flow chart in section 12 of this
manual. With remote fluid drains and removable doors,
virtually all components are accessible for maintenance and
service. Other features, including a spin-on compressor oil
filter and a drop-in separator element, reduce the time and
costs associated with routine maintenance.
The 20 HP VRUE also has enhanced safety features to
protect your valuable resources: minimum pressure valve,
high compressor oil temperature shutdown, low suction
pressure shutdown, high discharge pressure shutdown,
automatic blowdown device, pressure relief valves, and
clearly displayed warning/information decals.
2.1 General Information
Thank you for choosing the 20 HP VRUE Skid Compressor. Before
operating this system, read over this manual and become well ac-
quainted with your new machine. Doing this will increase your safety
and maximize the life of the machine.
While this manual is written to be as accurate as possible, Twin Stars,
Ltd. strives to continually improve the efficiency and performance of its
machines. As a result, sometimes there may be slight differences
between a given version of the manual and the machine.This manual must be read carefully before using your Twin Stars, Ltd. Gas Compres-
sor. Store in a safe and convenient location for future reference.
Service and
Maintenance
Manual
20 HP 8G VRUE
Skid Auto Bypass
Gas Compressor
309777-GN
07/24/2013
For technical support:
Phone: (505) 632-9202 (Outside USA)
Fax: (505) 632-2723 (USA)
Website: http://www.twinstars.com
9 309777-GN
Safety
3.1 General Safety Overview
Indicate[s] an imminently hazardous situation, which, if
not avoided, will result in death or serious injury.
Indicate[s] a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
Indicate[s] a potentially hazardous situation, which, if not
avoided, could result in minor or moderate injury.
Indicate[s] a potentially unsafe situation or practice,
which, if not avoided, can result in property and/or
equipment damage only.
Remember, 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 the safety of yourself and others. Lack of attention to
safety can result in: accidents, personal injury, reduction in efficiency, and worst of all Loss of Life.
Watch for safety hazards and correct them promptly.
Understanding the proper operation of this equipment is critical to its safe operation. The owner, lessor,
and/or operator of this equipment is hereby notified and forewarned that any failure to observe the
safety and operating guidelines may result in injury and/or damage. Twin Stars, Ltd. expressly disclaims
responsibility or liability for any injury or damage caused by failure to observe these specified precau-
tions or by failure to exercise the ordinary caution and due care required while operating or handling this
equipment, even though not expressly specified.
In addition to following these safety guidelines, the operator should follow any company specific guide-
lines and procedures. Consult your immediate supervisor for specific company safety guidelines and/or
procedures.
The following safety symbols are used throughout this manual to draw attention to important information.
If the information is not carefully read and the instructions are not followed, severe injury, death, and/or
damage to property and equipment may occur.
10 309777-GN
Safety
3.2 Safety Precautions
This is a pressurized system. Do not attempt to remove
any part of this machine without first completely relieving
entire system of pressure. Do not attempt to service any
part of the equipment while in operation. Never attempt
to repair or modify any pressure vessel or device.
The system is designed to compress gas. Do not attempt
to compress other gases. Compression of other gases
may create a situation where an explosion or fire may
occur.
Do not use flammable solvents for cleaning system com-
ponents as this can cause the unit to ignite or explode
during operation. Keep combustibles out of and away
from system inlets and any associated enclosures.
Never disable, override, or remove safeties, either tempo-
rarily or permanently.
The following safety precautions are a general guide to safe operation of the equipment.
System contains hot oil. The system must be shut off prior
to servicing. Then permit system to cool down prior to
adding compressor oil or servicing the unit.
Do not use gas from this system for breathing or food
processing. Gas from this system will cause severe injury
or death if used for breathing or food processing.
Never operate the machine in an enclosed area.
Do not modify systems to operate equipment at a higher
or lower pressure than specified.
11 309777-GN
Safety
3.2 Safety Precautions (continued)
Never place machine on a grade more than 15 degrees.
Keep doors closed on the machine during operation.
Use only Twin Stars, Ltd. approved replacement parts.
Substitution of components may impair suitability for Class
1 Division 2.
Do not replace any components unless power has been
switched off or the area is known to be non-hazardous.
Do not disconnect equipment unless power has been
switched off or the area is known to be non-hazardous.
Always properly connect grounding terminals.
Check the electric motors operator manual for
required service and maintenance intervals.
Tank heater can create a hazardous situation. Disconnect
power and allow tank heater to cool prior to performing
any maintenance, especially adding oil, to the system.
Failure to adhere will result in death or serious injury.
Read and understand this manual and all other safety
instructions before using this equipment. Failure to follow
operating instructions and/or failure to follow maintenance
procedures and intervals could result in personal injury,
death, and/or damage to equipment and property.
12 309777-GN
Safety
3.3 Safety and Information Decals
Pressurized SystemHot Pressurized Oil
Close Doors Overfill
This machine is supplied with a full complement of safety and identification decals. These decals are
affixed to the unit during final assembly. These decals must be clearly visible and undamaged. Should
any of these decals become illegible or damaged, immediately replace the decal.
Oil Level
Fan Guard
Hot Oil Read Manual
13 309777-GN
Safety
3.3 Safety and Information Decals (continued)
Serial Tag
VRU-100 Lubricant
Scrubber Drain Valve
System Inlet
By-Pass Valve
System Vent Valve
Compressor Drain Valve Direction of Rotation
Tank Heater
14 309777-GN
Specifications
*SPECIFICATIONS SUBJECT TO CHANGE WITHOUT PRIOR NOTICE*
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4.1 Specification Sheet
40.50
INLET
10.18
DISCHARGE7.81 33.00
71.89
123.82
53.70
60.26
124.47
104.75
51.21
15 309777-GN
Description of Components
The 20HP VRUE contains a 20 HP electric motor. The motor speed is regulated by a Variable
Frequency Drive (VFD). If the Speed Mode switch is in Manual the motor speed can be changed by
pressing and holding the Enter button on the control panel for 4 seconds, the display will change and
you will be able to use the Up and Down arrow buttons to adjust the motor speed, after the desired
speed is set press the Enter button again and the motor speed will change. If the Speed Mode switch is
in Auto the panel will automatically adjust the motor speed up as tank pressure increases and down as
tank pressure decreases.
5.1Electric Motor
5.2Drive Coupling
The drive coupling is a jaw type coupling. This is a type of motion control coupling designed to trans-
mit torque, by connecting two shafts, while damping system vibrations, which protects other compo-
nents from damage. Jaw couplings are composed of three parts: two metallic hubs and an elastomer
insert called a spider. The three parts press fit together with a jaw from each hub fitted alternately with
the lobes of the spider. The curved jaws of the hubs reduce deformation of the spider to maintain the
zero-backlash fit.
5.3 Compressor Gasend
The Twin Stars, Ltd. compressor gasend 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 electric motor is trans-
ferred through a gear set to the male rotor. The female rotor is driven by the male rotor. There are five
lobes on the male rotor while the female rotor has six roots. In operation, two helical grooved rotors
mesh to compress gas. Inlet gas is trapped as the male lobes roll down the female grooves, pushing
trapped gas along, compressing it until it reaches the discharge port at the end of the stator and delivers
smooth-flowing, pulse-free gas. Being an oil flooded system, the oil serves three purposes: lubricates
the rotating parts and bearings, serves as a cooling agent for the compressed gas, and seals the running
clearances. Gasend must be powered in the proper direction. Failure to rotate the gasend in the
correct direction will damage equipment and possible personal injury.
5.4 Separator System
I. Separator Tank
From the compressor gasend, the compressed gas and hot oil flow into a steel, ASME coded,
pressure vessel, rated at 250 PSI, that acts as an oil reservoir. This tank is the first of two stages in
separating the oil and compressed gas mixture. From the bottom of the separator tank, oil is forced
to the oil filter.
II. Separator Element
At the top of the separator tank is the separator element. The separator element removes the oil
mist from the gas as it is passed on to the minimum pressure valve. As the gas/oil mist passes
through the outside of the media, oil gathers on the interior walls and settles to the bottom of the
element. Collected oil is returned to the compressor gasend through the oil return line. The separa-
tor will filter the oil concentration in the gas to less than 3 parts per million.
16 309777-GN
Description of Components
I. Inlet Scrubber
The inlet scrubber is a two chambered, steel, ASME coded, pressure vessel that acts as a reservoir
for the inlet gas and helps separate moisture. Liquids from the upper chamber are drained into the
lower chamber and evacuated automatically. The gas in the upper chamber flows through a
demister pad and 1 micron filter to the inlet control valve.
II. Low Liquid Level Float Switch
The low liquid level float switch is mounted in the lower chamber of the inlet scrubber. When the
liquid level rises above the float switch, the switch closes, sending a ground to the common terminal
of the high liquid level float switch.
III. High Liquid Level Float Switch
The high liquid level float switch is located in the upper chamber of the scrubber. Should the liquid
level rise above the float, the float switch sends ground to the coil on the scrubber pump motor
starter contact, and a binary input on the controller. The pump continues to run until the liquid level
falls below the low liquid level float switch. If the liquid level does not fall below the high liquid level
float switch within 5 seconds, the machine will shut down on Hi ScrubberLvl.
5.5Inlet Scrubber System
5.7 Pressure Relief Valves
I. Separator Tank Relief Valve
This ASME coded valve vents separator tank pressure to atmosphere should the pressure inside the
tank exceed 250 PSI.
II. Inlet Scrubber Relief Valve
This ASME coded valve vents the upper chamber inlet scrubber pressure to atmosphere should the
pressure inside the vessel exceed 15 PSI.
5.6 Inlet Scrubber Pump
The inlet scrubber pump serves to evacuate any liquid that falls out of the gas stream from the bottom of
the inlet scrubber. The pump consists of the following components.
I. 3/4 HP, 3 Phase, 460V Electric Motor.
II. Gear Pump with 3/4 NPT Ports For Inlet and Discharge.
17 309777-GN
Description of Components
5.8 Cooling Systems
I. Compressor Oil Cooler
The compressor oil cooler is designed to dissipate the heat created during the compression of gas.
The oil cooler is mounted on top of the compressor aftercooler. Hot compressor oil is passed
through the interior of the cooler and heat is transferred to the air that passes across the cooling fins.
II. Compressor Aftercooler
The compressor aftercooler is designed to dissipate the heat load of the discharge gas and is
mounted below the compressor oil cooler. The gas exiting the aftercooler is lowered to within 15F
of ambient.
5.9 Compressor Oil Filter
The compressor oil filter is a full flow, spin-on canister. It has been specially designed to handle the full
system pressure. The oil filter is mounted downstream of the separator tank to ensure all contaminants
are prevented from being passed on to the compressor oil cooler.
5.10 Compressor Oil Thermal Valve
The compressor oil thermal valve is a thermostatically controlled by-pass valve that allows varying
amounts of oil, depending upon the temperature, to by-pass the oil cooler. The oil thermal valve directs
oil flow back to the compressor gasend until the system reaches 210F. Once at system operating
temperature, the valve shifts directing the flow through the oil cooler before returning to the compressor
gasend.
5.12 Minimum Pressure Valve
To ensure there is adequate pressure to produce proper oil flow throughout the system, a spring loaded,
normally closed minimum pressure valve is set to maintain at least 80 PSI in the separator tank.
5.11 Compressor Inlet Valve
The compressor inlet valve is a normally open gas intake valve bolted to the compressor gasend. This
valve has an NPT threaded connection. When the system is shut down, this valve also acts as a check
valve that prevents the gas/oil mixture within the compressor gasend from entering the inlet piping.
5.13 Blowdown Valve
The blowdown valve is a shuttle valve that vents system pressure to atmosphere when the system is shut
down. This is done to prevent the high torque load that would be required to overcome the static
pressure. The blowdown valve is stamped with an I and a P. The I side is connected to dry gas
from the separator tank, and the P side is the pilot signal coming from the compressor inlet valve.
18 309777-GN
Description of Components
5.14 Low Suction Bypass
The unit is equipped with a low suction bypass that allows a controlled amount of gas from the higher
pressure discharge side to recirculate to the inlet scrubber vessel, this is to prevent a vacuum from being
pulled on the tank(s). The bypass consists of a normally closed pneumatic motor valve and two normally
open solenoid valves. One solenoid valve allows gas to vent from the pneumatic valve into the suction
scrubber if the pressure in the tank(s) rises above the HiBypassSP, causing the motor valve to close.
The other solenoid valve allows regulated gas pressure (40 psig) to open the motor valve if the pressure
in the tank(s) falls below the LoBypassSP.
19 309777-GN
6.2 Placing The Machine
The first step in installing the 20 HP VRUE is set the system on a solid, level surface. This machine is
designed to run a level surface only. If you must set the package on any grade, set across the grade so
that the machine does not tend to roll. The machine must be supplied ample ambient air, as the system
will overheat if the cooling air intakes temperature exceeds ambient conditions.
Installation
6.1 System Installation Overview
The 20 HP VRUE should be installed only by those who have been delegated to do so, trained, and
who have read and understand this manual. Failure to follow the instructions, procedures, and safety
precautions in this manual may result in accidents and injuries.
Install, use, and operate this system only in full compliance with all pertinent O.S.H.A., Federal, State,
and Local codes or requirements, in addition to Twin Stars, Ltd. and any companys regulations.
Do not modify this system except with written factory approval.
6.3 Connecting the Gas Inlet Line
Verify the bypass valve is in the open position prior to supplying gas to the system. Connect the cus-
tomer supplied tank vent manifold to the 4 FNPT port on the inlet scrubber (4 is recommended for
the manifold and piping to the inlet scrubber, a shutoff valve at the inlet scrubber is also recommended).
ET SCRUBBER
VENT VALVE
BYPASS VALVE
4" FNPT
GAS INLET
INLET SCRUBBER
MANUAL DRAIN VALVE
2" FNPT
GAS DISCHARGE
COMPRESSOR OIL
DRAIN VALVE
ENVIRONMENTALLY SEA
FRAME DRAIN
7 FOOT LG. STAINLESS
STEEL VENT TUBE
SHIPPED LOOSE
5 FOOT LG. STAINLESS
STEEL VENT TUBE
SHIPPED LOOSE
1" MNPT INLET SCRUBBER
PUMP DISCHARGE
20 309777-GN
6.4 Connecting the Gas Discharge Line
Connect a customer supplied gas discharge line and check valve, designed to handle a minimum of 250
PSI continuously, to the 2 FNPT gas discharge port.
Installation
6.8 Machine Documentation
Record serial numbers for main components in the system.
I. Machine Serial Number __________________________________________
II. Compressor Gasend Serial Number __________________________________________
III. Electric Motor Serial Number __________________________________________
IV. Separator Tank Serial Number __________________________________________
V. Scrubber Serial Number __________________________________________
6.7 Pre-Startup Inspection
This inspection must be done prior to initial system startup.
I. Check all assemblies, clamps, fittings, hose connections, nuts, and bolts to ensure they are properly
tied and secured.
II. Remove all tools, rags, and installation equipment from the area.
III. Check all valves to ensure they are in the correct operating position.
A. Inlet Scrubber Vent Valve = Closed
B. Compressor Oil Drain Valve = Closed
C. Environmentally Sealed Frame Drain Valve = Closed
D. Inlet Scrubber Manual Drain Valve = Closed
6.6 Connecting the Electrical Lines
Connect a customer supplied electrical lines, in full compliance with all pertinent O.S.H.A., Federal,
State, and Local electrical codes or requirements. Ensure that the electrical lines are connected to the
motor, to provide proper rotation. Improper rotation will damage equipment and may cause personal
injury.
6.5 Connecting the Inlet Scrubber Pump Discharge Line
Connect a customer supplied scrubber dump line to the 1 NPT scrubber pump discharge port. A
check valve should be installed on the discharge line to prevent liquid back flow into the pump.
21 309777-GN
6.10 Initial Startup Preparation
I. Verify the disconnect is in the OFF position. Ensure there is proper voltage on the three legs coming
into the panel.
II. Check the system for gas, and/or oil leaks.
6.11 Initial Startup
The machine is factory filled prior to shipment. The proper fluid levels are also listed in the maintenance
section. The Separator Tank Oil Level should be halfway on the separator tank sightglass.
6.9 Check Fluid Levels
Installation
Directional arrows are attached to the compressor package on
both ends and sides of the electric motor. This coupling must be
rotating in the direction the arrows are pointing. If, for some
reason, this arrows have been removed, the correct compressor
rotation is counter-clockwise when looking directly at the com-
pressor shaft.
CONTACT TWIN STARS
FOR INITIAL STARTUP!
Phone: (505) 632-9202 (Outside USA)
Website: http://www.twinstars.com
22 309777-GN
Operation
7.1 Operation
CONTACT TWIN STARS
FOR OPERATION!
Phone: (505) 632-9202 (Outside USA)
Website: http://www.twinstars.com
The 20 HP VRUE should only be operated by those who have been delegated to do so, trained, and
who have read and understand this manual. Failure to follow the instructions, procedures, and safety
precautions in this manual may result in accidents and injuries.
Operate this system only in full compliance with all pertinent O.S.H.A., Federal, State, and Local codes
or requirements, in addition to Boss Industries, Inc. and any companys regulations.
23 309777-GN
Check electric motors operator manual for required service
and maintenance intervals.
Compressor oil filter is to be changed after the first 50 hours
of operation. After this, normal intervals are to be followed.
Maintenance
This section contains instructions for performing the inspection, lubrication, and maintenance procedures
required to ensure the system is in proper operating condition. The importance of performing the
maintenance described herein cannot be over emphasized. A planned program of periodic inspection
and maintenance will help avoid premature failure and costly repairs. Keep an accurate logbook for
maintenance, service, and operating hours. The maintenance schedule intervals on this system are
maximum intervals. The factory recommended maintenance schedule is based on favorable operating
conditions. For continuous duty, extreme temperature, etc., service more frequently. Neglecting routine
maintenance can result in machine failure or permanent damage.
This system should be maintained only by those who have been delegated to do so, trained, and who
have read and understand this manual. Failure to follow the instructions, procedures, and safety
precautions in this manual may result in accidents and injuries.
8.1 Maintenance Overview
8.2 Maintenance Schedule
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24 309777-GN
Maintenance
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Phone: (505) 632-9202 (Outside USA)
Website: http://www.twinstars.com
8.3 Recommended Spare Parts List
8.4 Parts and Service Contact Information
When calling for technical support, please have equipment
number, equipment and compressor serial numbers and this
manual available.
25 309777-GN
8.5 Maintenance Log
Maintenance
Accum.
Hours Date Service Performed Parts Replaced Service Work By
26 309777-GN
Maintenance
When the oil vapor in the discharge gas becomes excessive, the separator element may need replacing.
This should not be necessary more than once a year under normal operating conditions.
I. Replacement Procedure.
A. Shut down machine and allow to cool for approximately 10 minutes.
B. Verify entire system pressure is relieved before proceeding.
8.6 Separator Element Replacement
C. Disconnect the 1 hose from the minimum pressure valve.
D. Disconnect the two 1/4 hoses from the blowdown valve.
E. Disconnect the 1/4 hose from the oil return line.
F. Remove the eight 5/8 bolts holding the separator tank lid in place.
G. Lift and remove the lid from the package.
H. Remove the separator element.
I. Install a new element.
J. Reinstall the separator tank lid.
K. Reinstall the eight 5/8 bolts.
L. Uniformly tighten the bolts in a crisscross pattern to a torque of 220ft-lb.
M. Reconnect all hoses and ensure they are correctly located and tightened properly.
N. Start machine and check for any leaks.
Substitute filters may have inadequate working pressure
limits, resulting in filter leakage or rupture. Replacement
filters must be the same quality and type as the original Twin
Stars, Ltd. separator element.
When disconnecting hoses, be sure to note the location to
ensure there is no confusion when reconnecting.
Note the location of the separator tank lid so that it can
be reinstalled in the same orientation.
The separator tank lid has a scavenage line pick-up tube
installed and damaging or moving the tube will affect the
machines functionality.
The separator element flange must have a gasket on each side
to seal the lid on one side and the vessel on the other. The
staple in each gasket acts as a static ground and must not be
removed.
27 309777-GN
Maintenance
The life and proper operation of the system is dependent on adequate and clean oil. Twin Stars, Ltd.
VRU100 Synthetic Oil is supplied with the machine from the factory and should be used for proper
level maintenance and oil changes. It is advantageous to use VRU100 Synthetic Oil as it is an ideal oil
for this application.
8.7 Compressor Oil
I. Specifications
liOcitehtnyS001-URV dohteMtseT stluseR
edarGytisocsiVOSI 2242DMTSA 001
tsc,C04@ytisocsiV 544DMTSA 001
tsc,C001@ytisocsiV 544DMTSA 4.91
SUS,F001@ytisocsiV 544DMTSA 105
SUS,F012@ytisocsiV 544DMTSA 8.79
xednIytisocsiV 0722DMTSA 812
F06,ytivarGcificepS 8921DMTSA 540.1
F,tniopruoP 79DMTSA 94-
F,tniophsalF 29DMTSA 005
retcarahCevitneverPtsuR 566DMTSA ssaP
mm,gk04,F761,mpr0021,raeWllaBruoF 6622DMTSA 75.
noisorroCreppoC 031DMTSA A1
It is important that the system oil be of the recommended type,
inspected, and replaced as stated in this manual.
Mixing different types or brands of lubricants is not recom-
mended due to the possibility of a dilution of the additives or a
reaction between additives of different types.
28 309777-GN
Maintenance
F. Replace fill cap and tighten immediately.
III. Changing Compressor Oil
Initially the compressor oil and oil filter should be replaced after the first 50 hours of operation then
every 500 hours or as required based on strict oil analysis. Change oil at least annually or as
needed based on a strict oil analysis program or when contamination is apparent. Change oil filter
element at least annually or as needed based on differential pressure indication (maximum of 25 psi)
or operator experience. Life expectancy of compressor oil may vary from site to site. If the oil
appears dirty or has a foul smell, it should be replaced immediately.
A. Verify the machine is level to assure oil level sightglass will be accurate.
B. Remove any dirt around the separator tank fill cap to prevent contamination from entering the
system.
C. Remove the separator tank fill cap.
D. Inspect and clean the fill cap. Replace if necessary.
E. Drain oil from the bottom of the separator tank.
F. If compressor oil filter change is required, proceed to section 8.9, Compressor Oil Filter.
Do not remove caps, plugs, or other components when the
system is running or pressurized. Stop system and relieve all
internal pressure before doing so. Failure to comply with this
warning will cause damage to property and serious bodily
harm.
8.7 Compressor Oil (continued)
C. Remove the separator tank fill cap.
D. Inspect and clean the fill cap. Replace if necessary.
E. VRU-100 Synthetic Oil can then be added until the oil level reaches halfway in the sightglass.
Do not over fill the separator tank. This will cause oil carryover in the discharge line and at
blowdown.
II. Adding Compressor Oil
A. Verify the machine is level to assure oil level in sightglass will be accurate.
B. Remove any dirt around the separator tank fill cap to prevent contamination from entering the
system.
Do not remove caps, plugs, or other components when the
system is running or pressurized. Stop system and relieve
all internal pressure before doing so. Failure to comply
with this warning will cause damage to property and serious
bodily harm.
Do not replace fill cap with a pipe cap; serious injury or dam-
age could result. Replacement filters must be the same
quality and type as the original Twin Stars, Ltd. fill cap.
Tank heater can create a hazardous situation. Disconnect power and
allow tank heater to cool prior to performing any maintenance,
especially adding oil, to the system. Failure to adhere will result in
death or serious injury.
29 309777-GN
Maintenance
Initially the filter should be replaced after the first 50 hours of operation, then every 500 hours or as
required based on strict oil analysis. Change oil at least annually or as needed based on a strict oil
analysis program or when contamination is apparent. Change oil filter element at least annually or as
needed based on differential pressure indication (maximum of 25 psi) or operator experience. Life
expectancy of compressor oil may vary from site to site. A dirty filter can restrict oil flow, causing high
oil temperature, which will result in a system shutdown.
I. Compressor Oil Filter Replacement
A. Verify the compressor oil system is drained, and the system has fully blown down.
B. Using a strap wrench, remove the oil filter and o-ring.
C. Clean o-ring seating surface on the oil filter head.
D. Apply a light film of oil to the new o-ring.
E. Hand tighten new filter until o-ring is seated in o-ring groove.
F. Continue tightening filter by hand an additional 1/2 to 3/4 turn.
G. Continue with Changing the Compressor Oil steps.
8.9 Compressor Oil Filter
Substitute filters may have inadequate working pressure
limits, resulting in filter leakage or rupture. Replacement
filters must be the same quality and type as the original Twin
Stars, Ltd. oil filter.
Mechanical over-tightening may distort the threads or damage
the filter element seal.
H. Replace fill cap and tighten immediately.
I. Run system briefly to see if more oil needs to be added and to ensure there are no leaks.
Do not replace fill cap with a pipe cap; serious injury or dam-
age could result. Replacement filters must be the same
quality and type as the original Twin Stars, Ltd. fill cap.
8.8 Compressor Oil Cooler
Any sign of leakage from the compressor oil cooler justifies a pressure test to assure its integrity.
Cooler leaks should only be repaired by qualified service technicians. Dirt that clogs the cooling fins of
the cooler should be removed. The use of an air stream or high-pressure steam cleaner should be done
with caution so as to not damage the delicate fins. Bent cooling fins will reduce the cooling capability of
the compressor oil cooler.
8.7 Compressor Oil (continued)
III. Changing Compressor Oil (continued)
G. VRU-100 Synthetic Oil can now be added until the oil level reaches halfway in the sightglass.
Do not over fill the separator tank. This will cause oil carryover in the discharge line and at
blowdown.
30 309777-GN
Troubleshooting
9.1 Troubleshooting Chart
melborP esuaC ydemeR
detcepxenU
nwodtuhSderrucconwodtuhsytefaS esuacroflenaplortnockcehC
evissecxE
noitarbiV
rotomesoolrodegamaD
tnuomecalperroriapeR
deepsrotomwoL MPR009fomuminimdeepsrotomyfireV
edalbnafnekorbrotneB yletaidemmiecalperroriapeR
tonlliwenihcaM
erusserppudliub
nepoevlavnwodwolBecalper;skaelrofevlavfeilererusserpkcehC
dedeensa
rosserpmocnroW rosserpmocecalpeR
gnilpuocevirdytluaF gnilpuocecalpeR
sagtneiciffusnI
yreviled
rofdezisrednurosserpmoC
tnemeriuqersagtnemeriuqersagmumixamyfireV
deepsrotomwoL yrassecenfitsujda/deepsrotomkcehC
nepoevlavnwodwolBrofsnoitcennocdna,sgnittif,senilsagllakcehC
yrassecensariaper;skael
evlavtelniytluaF yletaidemmiecalperroriapeR
rosserpmocnroW rosserpmocecalpeR
gnilpuocevirdytluaF gnilpuocecalperroriapeR
evissecxE
liorosserpmoc
noitpmusnoc
dellifrevoknatrotarapeS levelreporpotlioniarD
metsysliorosserpmocnikaeLriaper;snoitcennocdnasenilgnipipllakcehC
yrassecensa
liognivomertonenilnruterliO
tnemelerotarapesmorf
riaper;snoitcennocdnasenilgnipipllakcehC
yrassecensa
degamadtnemelerotarapeS tnemeleecalpeR
rosserpmoC
gnitaehrevo
htiwaeranignitarepotinU
riahserfdetimiltnemenifnocpuneporotinunoitisopeR
snifrelooclionopu-dliubtriDottonluferaceb;ylhguorhtrelooclionaelC
snifegamad
wollevelliorosserpmoC levelreporpotllifdnakcehC
31 309777-GN
Troubleshooting
9.1 Troubleshooting Chart (continued)
9.2 Parts and Service Contact Information
Phone: (505) 632-9202 (Outside USA)
Website: http://www.twinstars.com
melborP esuaC ydemeR
rosserpmoC
gnitaehrevo
liorosserpmocninoitcirtseR
senilsenilecalperronaelC
detcirtseryllanretnireloocliO reloocfosebutlanretninaelC
ytridretlifliorosserpmoC retlifecalpeR
gninoitcnuflamevlavlamrehT evlavecalperroriapeR
rosserpmocnroW rosserpmocecalpeR
sroodhtiwmetsysgnitarepO
neposroodesolC
When calling for technical support, please have equipment
number, equipment and compressor serial numbers and this
manual available.
32 309777-GN
WARRANTYWarranty
10.1 Warranty
CONTACT TWIN STARS, LTD.
FOR WARRANTY!
Phone: (505) 632-9202 (Outside USA)
Website: http://www.twinstars.com
33 309777-GN
34 309777-GN
Parts and Illustration Section
11.1 Frame System
Parts List
ITEM QTY PART NUMBER DESCRIPTION
1 1 309517 SKID
3 4 305349-100 PLUG
4 1 302633 VALVE
5 1 305349-050 PLUG
6 4 937806-094 WASHER
7 4 938206-071 WASHER
8 4 929806-100 BOLT
9 1 303308 FILTER
10 2 960212-075 ELBOW
11 1 303277 HEAD
12 3 305358-000 NIPPLE
13 3 305343-075 TEE
14 1 984109-075 ELBOW
15 1 305651 THERMOSTAT
16 2 305357-100 BUSHING
17 2 305356-000 NIPPLE
18 1 305343-200 TEE
19 1 305341-200 ELBOW
20 2 305359-025 BUSHING
21 1 309068 BRACKET
22 1 309067 GAUGE
23 1 960104-025 CONNECTOR
24 1 960216-100 ELBOW
25 2 305012 CONNECTOR
26 2 960112-075 CONNECTOR
27 1 960204-025 ELBOW
28 1 300111 CLAMP
29 1 929705-100 BOLT
30 1 305511-000 NIPPLE
31 1 960108-050 CONNECTOR
32 1 309728 BRACKET
33 1 960116-100 CONNECTOR
34 1 309821 THERMOSTAT
35 2 924304-145 NUT
36 2 938604-071 WASHER
37 2 929104-125 BOLT
38 1 922208-000 NIPPLE
39 1 904415-020 TEE
35 309777-GN
11.1 Frame System (continued)
Parts and Illustration Section
OIL
FLOW
8
6
7
32
304
31
5
28
29
33
26
3
3
13
14
19
27
26
13
20
12
13
25
22
24
217
6
8
17
1817
23
1210
20
1211
10
16
15
9
3
16
1
C
BA
34
35
36
37
3
39
38
36 309777-GN
11.2 Motor System
Parts and Illustration Section
Parts List
DESCRIPTIONPART NUMBERQTYITEM
MOTOR30886411
NUT925508-26242
WASHER938208-112163
BOLT929808-20044
WASHER937808-12585
BOLT929808-15046
BRACKET30890417
FAN30891118
ADAPTER30891219
BOLT929808-125410
WASHER938910-200411
WASHER938810-220412
BOLT929210-450413
CLAMP300111114
37 309777-GN
11.2 Motor System (continued)
Parts and Illustration Section
CLOCKWISE
ROTATION
14
3
6
5
3
4
3
6
3
3
2
10
9
12
13
3
4
34
2
1
11
3
5
57
8
38 309777-GN
11.3 Compressor System
Parts and Illustration Section
Parts List
DESCRIPTIONPART NUMBERQTYITEM
GASEND301709-36911
ADAPTER970804-02512
ADAPTER970816-10013
VALVE30477114
WASHER938908-18045
WASHER938808-20046
BOLT928008-25047
COUPLING305355-20018
PLUG902915-01029
ELBOW305401110
CONNECTOR960104-038111
CONNECTOR973112-050112
GASKET302467113
NIPPLE305356-240-MOD114
SENDER307381115
HUB308915116
SPIDER302134117
HUB308916118
TEE961804-025119
CONNECTOR303920120
VALVE304012121
ELBOW960704-025122
TEE309760123
39 309777-GN
11.3 Compressor System (continued)
Parts and Illustration Section
CLOCKWISE
ROTATION
23
19
4
11
13
9
20
21
22
6
5
7
1
16
17
12
15
2
14
8
3
18
10
40 309777-GN
11.4 Discharge System
Parts and Illustration Section
Parts List
DESCRIPTIONPART NUMBERQTYITEM
TANK30884611
SIGHTGLASS30010712
CONNECTOR960124-15013
CAP301466-15014
ELBOW960204-02545
VALVE30808716
CONNECTOR30402227
TUBE30421018
ELBOW960304-02519
NIPPLE960404-025210
CONNECTOR960104-025111
VALVE305518112
ORIFICE304592-078113
TEE305343-150114
BUSHING305359-050115
TEE305343-075116
ELEMENT124-22414117
WASHER938208-112418
BOLT929808-150419
WASHER937808-125420
ELBOW984124-150121
HEATER308907122
CONNECTOR960116-125123
BUSHING305357-100124
ELBOW960724-150125
BUSHING305344-125126
NIPPLE305345-050127
ADAPTER307968128
ELBOW960212-100129
VALVE306075-250130
VALVE303450131
TRANSDUCER309443132
CONNECTOR910216-100133
PLUG902915-005134
TUBE3093607 ft35
CONNECTOR960116-100136
ELBOW960208-075 137
NIPPLE305358-000138
41 309777-GN
11.4 Discharge System (continued)
Parts and Illustration Section
24
36
35
17
10
75
531
5
12
13
11
34
3233
5
"I"
"P"
28
30
15
8
22
29
19
20
18
7
9
2526
23
4
3
14
212
27 6
1
1638
37
42 309777-GN
11.5 Cooler System
Parts and Illustration Section
Parts List
DESCRIPTIONPART NUMBERQTYITEM
COOLER ASSY30888511
WASHER938604-071202
WASHER938004-062163
BOLT929104-100104
GUARD30886825
BULKHEAD309056-GN16
WASHER938206-071187
WASHER937806-09468
BOLT929806-100129
ELBOW960212-075210
ELBOW960216-100211
NUT925506-198612
SHROUD308902113
NUT924304-145214
GUARD309127-GN115
BOLT929104-075816
43 309777-GN
11.5 Cooler System (continued)
Parts and Illustration Section
11
62
316
15
9
7
2
4
3
2
9
87
12
10
102
3
4
87
12
71
13
5
14
2
5
4
7
11
9
44 309777-GN
11.6 Scrubber System
Parts and Illustration Section
Parts List
ITEM QTY PART NUMBER DESCRIPTION
1 2 303060 SWITCH
2 5 305348-000 NIPPLE
3 4 960116-100 CONNECTOR
4 6 938208-112 WASHER
5 3 925508-262 NUT
6 3 929808-150 BOLT
7 2 305343-100 TEE
8 1 305348-060 NIPPLE
9 1 306830-015 VALVE
10 2 305341-100 ELBOW
11 3 304551-100 VALVE
12 1 305229 FILTER
13 1 960204-025 ELBOW
14 2 960216-100 ELBOW
15 1 305348-030 NIPPLE
16 1 960016-100 ELBOW
17 1 305401 ELBOW
18 1 305356-000 NIPPLE
19 1 902915-040 PLUG
20 2 305348-050 NIPPLE
21 1 960204-012 ELBOW
22 1 305348-040 NIPPLE
23 1 309277 VALVE
24 2 309278 SOLENOID
25 2 960104-025 CONNECTOR
26 1 305352-020 NIPPLE
27 1 305349-025 PLUG
28 1 307968 ADAPTER
29 1 960404-025 NIPPLE
30 1 985200-040 CROSS
31 1 305350-025 BUSHING
32 1 910216-100 CONNECTOR
33 1 960704-025 ELBOW
34 1 961604-012 NIPPLE
35 1 309708 REGULATOR
36 1 960702-012 ELBOW
37 1 309709 GAUGE
38 1 300107 SIGHTGLAS
39 1 960216-125 ELBOW
40 5 ft 309360 TUBE
41 1 994116-020 STRAINER
42 1 40057-2-GN BLOWCASE TANK
45 309777-GN
11.6 Scrubber System (continued)
Parts and Illustration Section
GAS
FLOW
12
3
6
44
5
112
7
8
10
15
1
14
20
7 163
11
2
112
10
2
18
17
9
22
23
3
25
26
24
29
28
25
2
31
30
32
27
13
19
14
1
39
40
33
34
35 21
37
36
2241
3
38
42
46 309777-GN
11.7 Decal System
Parts and Illustration Section
Parts List
DESCRIPTIONPART NUMBERQTYITEM
DECAL, TWIN STARS LOGO30523311
DECAL, SERIAL TAG BOSS30576112
DECAL, DANGER HOT OIL30003813
DECAL, WARNING READ MANUAL30003914
DECAL, BGB ALL IN ONE SHEET30721015
DECAL, VENT BGB30721215A
DECAL, INLET BGB30721415B
DECAL, BY-PASS BGB30721315C
DECAL, SCRUBBER DRAIN BGB30586015D
DECAL, DOORS CLOSED104-9002925E
DECAL, COMPRESSOR OIL DRAIN BGB30525415F
DECAL, WARNING FAN GUARD30004125G
DECAL, OIL RESERVOIR104-9011515H
DECAL, HOT OIL104-9011215I
DECAL, DO NOT OVERFILL104-9012015J
DECAL, COMPR SIGHT GLASS30256815K
DECAL, DIRECTION OF ROTATION30004846
DECAL, TEMP. COMPR.- 250 F30159417
DECAL, FACTORY FILLED VRU-100 OIL30886918
PLACARD, SKID TWIN STARS30972019
RIVET943102-018410
DECAL, DANGER TANK HEATER310024111
DECAL, 240 VAC310064112
47 309777-GN
DETAIL A DETAIL B
DETAIL C
DETAIL DDETAIL E
DETAIL F
DETAIL H
DETAIL I
DETAIL G DETAIL J
5B
5A
5C
5D
109
5E 2
5F
5G
6
6
4
3
8
5H
5I
5J
5E
1
6
5K
5G
6
11
12
11.7 Decal System (continued)
Parts and Illustration Section
48 309777-GN
11.8 Canopy System
Parts and Illustration Section
Parts List
DESCRIPTIONPART NUMBERQTYITEM
CANOPY309519-GN11
LATCH30138382
PANEL309058-GN13
DOOR309059-GN24
COVER309060-GN15
RIVET994204-025206
WASHER977004-062247
WASHER984004-071248
BOLT983904-075219
ROOF309061-GN110
DOOR309062-GN211
WASHER938206-071812
WASHER937806-094813
BOLT929806-125814
WASHER938604-071315
NUT924304-145316
BOLT983904-100317
49 309777-GN
11.8 Canopy System (continued)
Parts and Illustration Section
DETAIL A
8-PLACES
A
16
15
17
1
11
2
11
2
3
6
78
9
5
79
8
10
4
2
2
4
12
13
14
50 309777-GN
Parts and Illustration Section
11.9 Electrical Water Pump System
Parts List
DESCRIPTIONPART NUMBERQTYITEM
MOTOR30977011
PUMP30979612
ELBOW960216-07513
NIPPLE961616-07514
WASHER938605-071125
NUT924305-16666
BOLT929105-12567
PLATE30979518
51 309777-GN
Parts and Illustration Section
11.9 Electrical Water Pump System
4
2
3
5
6
8
5
7
1
52 309777-GN
Parts and Illustration Section
11.10 System Wiring Diagram
53 309777-GN
11.11 Hose System
Parts and Illustration Section
REBMUNTRAP NOITPIRCSED
061-719303
DAEHRETLIFLIOFOTUO&NIOTEGUAGERUSSERPLAITNEREFFID.1
REBBURCSTELNINOSSORCOTDIONELOS.C.N.2
TNEVNWODWOLB.3
204503EVLAVFEILERYTEFASESACWOLBOTEVLAVTNEVREBBURCSTELNI.1
NIARDRETAW.2
848703 DAEHRETLIFLIOOTKNATROTARAPESFOEDIS
861303 RELOOCRETFAOTEVLAVERUSSERPMUMINIM
073-719303 ROSSERPMOCFORAEROTNRUTERLIO
533-719303 TROPTOLIPNWODWOLBOTEVLAVTELNIFOEDIS
930903 RELOOCNOTROPMOTTOBOTEVLAVLAMREHTFOPOT
040903 EVLAVLAMREHTNOEETOTRELOOCNOTROPPOT
240903 EVLAVNIARDETOMEROTKNATROTARAPESFOMOTTOB
140903 TROPNOITCEJNILIOOTEVLAVLAMREHTNOEET
941403EETEGRAHCSIDOTEVLAVSSAPYB.1
KNATROTARAPESFOEDISOTEGRAHCSIDROSSERPMOC.2
340903 EVLAVTELNIOTREBBURCSTELNIFOPOT
0321-719303TAOLFEGRAHCSIDDIUQILOTEVLAVERUSSERPMUMIMIMFOEDIS
HCTIWS
761303 EETEGRAHCSIDOTRELOOCRETFA
072-719303 TNEVNWODWOLBLAUNAM
018703 ENILECNALABREBMAHCREBBURCSTELNI
838703 TELNIPMUPRETAWOTEGRAHCSIDREBBURCS
54 309777-GN
Parts and Illustration Section
11.12 Gas/Oil Schematic
55 309777-GN
Flow Chart Section
12.1 SCG8G Flow Chart
Horsepower (HP) shown is the compressor input shaft
ONLY. The cooling fan requires 1.5 horsepower. Add
the cooling fan HP to the chart above for total HP.
MSCFD @ 1,775 RPM
50 60 70 80 90 100 125 150 175 200
0.0 62 62 62 62 61 60 58 56.5 55 53.5
0.5 64.5 64.5 64.5 64.5 63.5 62.5 60.5 59 57.5 --
1.0 66.5 66.5 66.5 66.5 65.5 64.5 62.5 61 59.5 --
1.5 69 69 69 69 69 68 66 64.5 -- --
2.0 71 71 71 71 70 69 67 -- -- --
2.5 73 73 73 73 72 71 69 -- -- --
3.0 75.5 75.5 75.5 75.5 74.5 73.5 71.5 -- -- --
3.5 78 78 78 78 77 76 -- -- -- --
4.0 80 80 80 80 79 78 -- -- -- --
4.5 82 82 82 82 81 80 -- -- -- --
5.0 84 84 84 84 83 -- -- -- -- --
H.P. @ 1,775 RPM
50 60 70 80 90 100 125 150 175 200
0.0 14.5 14.6 14.7 14.9 15.5 16 18 19 19.5 20
0.5 14.9 15 15.1 15.3 15.9 16.4 18.4 19.4 19.9 --
1.0 15.2 15.3 15.4 15.6 16.2 16.7 18.7 19.7 20 --
1.5 15.5 15.6 15.7 15.9 16.5 17 19 20 -- --
2.0 15.8 15.9 16 16.2 16.8 17.3 19.3 -- -- --
2.5 16.1 16.2 16.3 16.5 17.1 17.6 19.6 -- -- --
3.0 16.4 16.5 16.6 16.8 17.4 17.9 19.9 -- -- --
3.5 16.7 16.8 16.9 17.1 17.7 18.2 -- -- -- --
4.0 17 17.1 17.2 17.4 18 18.5 -- -- -- --
4.5 17.3 17.4 17.5 17.7 18.3 18.8 -- -- -- --
5.0 17.6 17.7 17.8 18 18.6 -- -- -- -- --
SUCTION PRESSURE (PSI)
SUCTION PRESSURE (PSI)
DISCHARGE PRESSURE (PSI)
DISCHARGE PRESSURE (PSI)