Service and Maintenance Manual Gas Compressorbossair.com/Manuals/309777-GN MANUAL, 20HP VRUE TWIN STAR… · Service and Maintenance Manual 20 HP 8G VRUE Skid Auto Bypass Gas Compressor

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:


Fax: (505) 632-2723 (USA)


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


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


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


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!



22 309777-GN

Operation

7.1 Operation

CONTACT TWIN STARS

FOR OPERATION!



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


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


8.1 Maintenance Overview

8.2 Maintenance Schedule

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24 309777-GN

Maintenance

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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

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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


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



melborP esuaC ydemeR

rosserpmoC

gnitaehrevo

liorosserpmocninoitcirtseR

senilsenilecalperronaelC

detcirtseryllanretnireloocliO reloocfosebutlanretninaelC

ytridretlifliorosserpmoC retlifecalpeR

gninoitcnuflamevlavlamrehT evlavecalperroriapeR


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!



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)


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 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)


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 List


GASEND301709-36911

ADAPTER970804-02512

ADAPTER970816-10013

VALVE30477114

WASHER938908-18045

WASHER938808-20046

BOLT928008-25047

COUPLING305355-20018

PLUG902915-01029

ELBOW305401110

CONNECTOR960104-038111


GASKET302467113

NIPPLE305356-240-MOD114

SENDER307381115

HUB308915116

SPIDER302134117

HUB308916118

TEE961804-025119

CONNECTOR303920120

VALVE304012121

ELBOW960704-025122

TEE309760123

39 309777-GN

11.3 Compressor System (continued)


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 List


TANK30884611

SIGHTGLASS30010712


CAP301466-15014

ELBOW960204-02545

VALVE30808716

CONNECTOR30402227

TUBE30421018

ELBOW960304-02519

NIPPLE960404-025210


VALVE305518112

ORIFICE304592-078113

TEE305343-150114

BUSHING305359-050115

TEE305343-075116

ELEMENT124-22414117

WASHER938208-112418

BOLT929808-150419

WASHER937808-125420

ELBOW984124-150121

HEATER308907122


BUSHING305357-100124

ELBOW960724-150125

BUSHING305344-125126

NIPPLE305345-050127

ADAPTER307968128

ELBOW960212-100129

VALVE306075-250130

VALVE303450131

TRANSDUCER309443132


PLUG902915-005134

TUBE3093607 ft35


ELBOW960208-075 137

NIPPLE305358-000138

41 309777-GN

11.4 Discharge System (continued)


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 List


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)


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 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)


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 List


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)


48 309777-GN

11.8 Canopy System


Parts List


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)


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


11.9 Electrical Water Pump System

Parts List


MOTOR30977011

PUMP30979612

ELBOW960216-07513

NIPPLE961616-07514

WASHER938605-071125

NUT924305-16666

BOLT929105-12567

PLATE30979518

51 309777-GN


11.9 Electrical Water Pump System

4

2

3

5

6

8

5

7

1

52 309777-GN


11.10 System Wiring Diagram

53 309777-GN

11.11 Hose System


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


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)

Documents

Service and Maintenance Manual Gas Compressorbossair.com/Manuals/309777-GN MANUAL, 20HP VRUE TWIN STAR… · Service and Maintenance Manual 20 HP 8G VRUE Skid Auto Bypass Gas Compressor