Baldor BD Series User manual

1
SCREW AIR COMPRESSOR
USER MANUAL
GUANGDONG BALDOR-TECH CO., LTD.
Add: NO.3 Lemin Avenue, Leping Town, Sanshui, Foshan, Guangdong.
phone：[phone] fax：[phone]
website：http://www.baldor-tech.com

2
DIRECTORY
CHAPTER ONE：SAFTY ATTENTION......................................................................................4
CHAPTER TWO：INSTALLATION STANDARDS AND REQUIREMENTS ........................5
A、HANDLING ATTENTION.......................................................................................................5
B、INSTALLATION ENVIRONMENT LAYOUT REQUIREMENTS.................................... 6
C、INSTALLATION PROPOSALS.............................................................................................. 7
D、INSTALLATION REQUIREMENTS......................................................................................8
E、THE CONFIRMATION OF AIR SUPPLY SCHEME............................................................9
F、THE CONFIRMATION OF AIR CAPACITY...................................................................... 10
CHAPTER THREE：MACHINE SYSTEM STRUCTURE，PROCESS AND FUNCTION..11
A、AIR END STRUCTURE AND WORKING PRINCIPLE...................................................11
B、SYSTEM FLOW CHART.......................................................................................................13
CHAPTER FOUR：ELECTRICAL CONTROL SYSTEM AND CIRCUIT..............................14
A、LOW VOLTAGE POWER SUPPLY AND PERIPHERAL CONNECTION REQUEST.14
B、CONTROL SYSTEM FUNCTION....................................................................................... 15
C、ATTACHMENT.......................................................................................................................17
CHAPTER FIVE:PIPE LINE CONFIGURATION AND INSTALLATION............................... 20
CHAPTER SIX: OPERATIONAL GUIDELINES......................................................................... 23
CHAPTER SEVEN:DAILY MAINTENANCE..............................................................................25
A、LUBRICATING OIL SPECIFICATION AND USE............................................................26
B、CONTROL DEVICE ADJUSTING...................................................................................... 27
C、THE MAINTENANCE OF MACHINE CONSUMABLE PARTS....................................28
D、THE MAINTENANCE OF SCREW AIR COMPRESSOR............................................... 29
CHAPTER EIGHT:COMMON FAULTS AND PROCESSING................................................... 30
CHAPTER NINE: MANTENANCE RECORD............................................................................. 35

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THANK YOU FOR CHOOSING BALDOR
SCREW AIR COMPRESSOR
GUANGDONG BALDOR-TECH CO., LTD has the right to
change the design. But it is not responsible for the corresponding
modification and improvement of products out of the factory. Later
we may change the specifications and parts of the products without
prior notice.
The machine has past strict inspection and testing before they
leave the factory. In order to ensure the machine works safely, in
long-term use and good working condition, please read the user
manual before machine works. Do not change the parameter which
has been adjusted in the factory.

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Chapter One：Safety Attention
Read it carefully before operating the air compressor safely
1. Before install the piping welding, move the near flammable items and prevent welding spark
dropping into the air compressor.
2. The power of the air compressor supplying line must be matched with air switch, fuse and the
other safety device. The line must have grounding device. Install lightning protection device if it is
necessary.
3. The machine must be tested by our company or approved personnel.
4. Pay attention to the rotating direction of the machine when start the machine for the first time or
change the power line.
5. The air compressor can't work upon the exhaust pressure that is higher than the nameplate
prescribed.
6. Do not sure to start machine forcibly when the air compressor is in malfunction condition or
there’s unsafe factors. Should cut off the power supply, and make a significant mark.
7. Compress air and electrical appliances are dangerous. Make sure the power supply has been cut
off when repair or maintain it. And hang "repair" or "no switching" marks in the power place.
8. Must wait the air compressor cools down and the air is released safely, repair or maintain it when
the internal pressure of machine is equal to atmospheric pressure.
9. Use no corrosive safe fusing agent to clean the machine parts. It is strictly prohibited to use
flammable and volatile cleaner.
10. Regularly check the safety valve and the other protection system after operating the air
compressor for a period time, and ensure it is sensitive and reliable. Check it once per year
generally.
11. The parts of air compressor must be provided by original factory, and the oil must be our
company designating screw air compressor oil. Does not mix use two different brands of oil;
otherwise it will cause system coke to a serious accident.

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12. Air compressor should be operated by permanent staff. Operator should read through and
understand the contents of this manual, following the instructions of the working procedures, safety
precautions and maintenance instructions.
13. The compressor can not be directly used as produce breathing equipment, if you want to achieve
breathing standard, compressor should do corresponding purification treatment.
14. The machine door should be closed when it working. Only open for inspecting in a short time.
Avoid the harm to human body by the working parts and high temperature parts of it.
15. Pressure vessel can not be welding repair and not use fire for inspection machine or the internal
parts.
All violate of safe matter behavior may cause serious accidents.
Chapter Two：Installation Standards And
Requirements
a、HANDLING ATTENTION
1. In order to carry safely, pay attention to the total weight of the machine.
2.To ensure balance when the crane carry, pay attention to the placing of steel wire rope.
Prepare slings to prevent the steel wire rope extruding, which will damage the body.
3. Use the soft liner protection to prevent compressor surface damaging when forklift carry.
Forklift fork should insert the air compressor base completely.

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b、INSTALLATION ENVIRONMENT LAYOUT REQUIREMENTS
1. Machine room should be close to the load centre, so as to shorten the length of pipe, reduce
the pressure loss & power consumption, and guarantee the air supply pressure.
2. Consider the rationality of the power supply, water supply when planning the room
position.
3. There should be enough lands for expanding around the room in order to adapt to the
needs of the development.
4. Air compressor directly sucks air. In order to lower the possibility of the machine’s
wearing, corrosion and explosion, there must be a certain distance between the air
compressor room and the place which sends out explosive, corrosive, poisonous gas, dust and
other harmful substances. What’s more, the room should be located in the place of the
minimum frequency wind to make sure it is affected the least by harmful substances. The
distance between compressor and harmful substance emission source is suggested. Please see
the table2-1 below.
Distance between compressor and harmful substance emission source
the name of harmful substance
emission source
the relation with the
wind orientation
level distance(m)
the place which will send out
flammable gas(acetylene, gas)
any wind orientation
≥20
the chimney and discharge pipe
which send out dust
The underside of local
minimum frequency wind
≥50
the place which sends out dust
unfavorable wind
favorable wind
≥50
≥20

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1. Due to the large heat release of the compressor, especially in summer, the inner
temperature is high, so the machine room should be well ventilated and less sunlight.
2. Though there is a case outside the air compressor, it is strictly prohibited from rain and
sunlight. Therefore, the compressor should not be installed outdoor.
3. The compressor room should be set up as an independent building. The minimum distance
with other buildings, structures is as the table 2-2 below:
Workshop fire prevention distance
fire prevention distance(m)
fire resistant rating
1st & 2nd
grade
3rd
grade
4th
grade
1st & 2nd grade
10
12
14
3rd grade
12
14
16
4th grade
14
16
18
c、INSTALLATION PROPOSALS
1、the smallest installation space of air compressor(mm)

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d、INSTALLATION REQUIREMENTS
1. Leave enough room for repairing and maintaining the air compressors.
2. The ground is best to be smooth cement floor. The air compressor base should be placed at
the concrete platform above the ground 150 mm high, and platform levelness is not more than
0.5/1000 (mm). And there should be grooves around and on the platform, and then the oil and
water can flow away through the groove when stopping the machine for changing oil,
repairing or washing the ground. The size of the groove is decided by the user.
3. Make sure the bottom of the compressor is placed evenly on the platform, which can
minimize vibration and noise.
4. For users in good economic condition, acoustic board can be fixed on the inner wall to
further reduce the noise, but should not use ceramic tile or the other hard surface materials.
.5. Air cooled type compressor is much influenced by environmental temperature, so the
room should be ventilated, dry, inner with exhaust fan. The environment temperature of
compressor should be controlled within - 5 ℃~ 40℃.
6. The air of workshop should be clean, no dust, harmful gases, sulfurous acid and the other
corrosive medium.
7. Air compressor is heating equipment, especially the cooled type compressor, so the
ventilation of workshop is very important. It is necessary to install the air draft equipment in
accordance with the outside wind orientation. The pumping volume must be higher than that
of air compressor cycle fan or cooling fan, and cooling air inlet area should be large enough.
Also can install a guiding wind hood at the top of the air compressor’s air exhaust fan, which
can siphoned off the hot air discharged by the air compressor through the pipe to maintain
the room temperature within 5 ~ 40 ° C.
When using exhaust pipe, leave enough space to install canvas active connector for
maintenance (for example, when cleaning cooling unit, there’s enough space dismantling
compressor cover and the other parts).

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e、THE CONFIRMATION OF AIR SUPPLY SCHEME
According to the workshop size, air distribution, the air supply pressure level, air quality
grade and other factors, we confirm several air supply plans by comprehensive consideration
and technical & economic comparison.
1. The chief air compressor station supplies air.
That is built a chief air compressor station to provide all the air users. This scheme is
suitable for small, medium-sized factories and users quite centralized in large factories.
2. Regional air compressor station supplies air.
When factory is big, air consumption is large and the main users are dispersive, to avoid
the pipe is too long causing pressure drop and ensure the air supply to main users, often use
this air supply plan. There should be pipes connecting each other among the regional stations
to adjust the load and share mutually. At the meantime, should consider the reserved volume
and units of the station together.
3. supply air on the local
When the air consumption in the factory is small and users are less and dispersive, there
is use small compressor to supply air on the local. The machine can be placed on one end of
the workshop or slope room and also can be placed near the using point.
4. supply air with a plan of combining centralization and dispersion
In some large and medium-sized factories, the main air compressor users concentrate,
secondary users are much dispersive, or each team user imbalance, especially uses imbalance.
Under this condition should use this plan.

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f、THE CONFIRMATION OF AIR CAPACITY
1. Calculate the air capacity according to the sum of average consumption
hmKQQ /)1( 3
32102  
2
Q
：air capacity
hm /
3
0
Q
：
hm /
3
:sum of air compressor or workshop average consumption
K
：Consumption inequality (maximum) coefficient 1.2-1.4
1

：The leakage coefficient of connect pipeline. When the pipe length is less than 1 km, take
0.1; Shorter than 0.5 km, take 0.15; Longer than 2 km, take 0.2.
2

：using air equipments wearing consumption coefficient is 0.15 ~ 0.2
3

：Unforeseen consumption coefficient is 0.1.
2. Calculate the air capacity according to maximum consumption
hmKQQ /)1(max 3
321
'
22  
max
Q
：
hm /
3
sum of using air equipment or workshop average consumption
'
2
K
：The coefficient during the same period (according to various industries, by empirical data, it can
also be determined with reference to the
'
2
K
value of the similar projects).
1

，
2

，
3

the same with the above

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3. Calculate the air capacity according to comprehensive situation
 
 
hmQQQ /1 3
321012  
1
Q
：the maximum consumption of the main using air equipment
0
Q
：the average consumption of other using air equipment
This method can be used for the individual high air consumption equipment. Calculate the capacity of the
air compressor station which
1
Q
and
0
Q
are very different.
Among the three calculation methods, each industry should choose it according to the characteristics of the
industry, the traditional habit and experience.
When the purification system with a heat or no heat regenerative adsorption dryer, the air capacity should
be each increased 8% ~ 10% or 15% ~ 20% regeneration air consumption.
In plateau area, the air capacity should also take consider of the height of the region multiplied by the
following table 2-3 plateau correction coefficient.
Plateau correction coefficient
altitude(m)
0
305
610
914
1219
1524
1829
2134
2438
correction
coefficient
1.0
1.03
10.7
1.10
1.14
1.17
1.20
1.23
1.26
Chapter Three: Machine System Structure,
Process And Function
a、airend structure and working principle
1、the schematic diagram of screw air compressor air end

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2、working principle
Working cycle can be divided into three processes: suction, compression and exhaust.
2.1 suction process
As shown in picture a (screw compressor suction process), the pair of gear is arrowed. Male rotor rotate
clockwise and female rotor anti-clockwise. As in the picture a, the rotor end is for exhaustion. When the
rotor rotates, the gear meshing with each other in the inlet end gradually disconnect, thus the composition
of the gear space volume increase gradually, and it connects with the air inlet, beginning to breathe in.
Rotor continues to rotate, and gear space volume increase. When gear space volume achieves the maximum,
that is, the gear with suction orifice is off, the suction process is over.
2.2 compression process
As shown in picture b, it is the compression process of screw compressor. Male and female rotor gear
mesh with each other to form a complete sealing connecting line and the air is surrounded in a closed
volume by rotor gear and casing. When the rotor rotates, the gear connecting line moves towards the
exhaustion end and the closed volume among tooth gradually decreases, and its air pressure increases.
When the gear space volume connects with
the exhaust orifice, air is compressed over.
2.3 exhaust process
As shown in picture c, gear space volume is divided by the rotor connecting line into low pressure side
and high side. When the volume of high pressure side connects with the exhaust orifice, which is the exhaust
process, the volume of low pressure side is in suction process. Along with the rotor rotating, the volume of
high pressure side reduces to zero, and the air is all discharged. At the same time, volume of the low
pressure side achieves maximum, completing the suction process. So that the suction, compression,
exhaustion processes go cycling.

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b、system flow chart
Air compressor process includes air system, lubricating oil system and cooling system.
1 air system process
After air into the air filter removing dust, it is compressed in the air end through the inlet valve. The
compressed oil mixing with air go into the oil-air separator, then the filtered air go through the minimum
pressure valve, cooler, air water separator, and finally discharge by the air-supply valve (air water
separator can be installed after the air supply valve, according to the needs of users). The separated oil
stays in oil-air separator tank, then go into the oil circulation system.
2lubricating oil system process
Lubricating oil system is composed of oil and gas separator, temperature control valve, oil cooler, oil
filter, etc. The oil in oil-air separator is driven into oil pipe under the air pressure, then goes through the
temperature control valve, oil cooler and the oil filter, finally is divided into two flows, one flow injecting to
air end, another flow into the front and back bearing to lubricate the bearing. The two flows are combined
in the air end, mixing with the air, going into the oil-air separator, separated by the oil-air separator, staying
in oil-air separator, and into the next cycle.

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3cooling system process
Screw air compressor is divided into air cooling type and water cooling type, through the fan or
water forcing cooling.
Air cooling system consists of cooling fan, oil coolers and air cooler. The cooled air is pumped into
the fan; go through oil cooler and air cooler, and at the same time, cool and compressing lubricating oil and
air. Please pay attention to the cleaning and maintaining of the cooler surface.
Water cooling system mainly consists of the water cooler, including oil-water cooler and air-water cooler,
cooling air and oil at the same time. The water supply system is installed by the customer. Please pay
attention to the cooling water managing.
Chapter Four: Electrical Control System And
Circuit
a、Low voltage power supply and peripheral connection request
1、Low voltage power is alternating current three phase 380V, 50Hz.
2、Voltage drop will be no more or no less than 5% of the rated voltage, and the phase voltage
variance is within 3%. And there should be phase sequence protecting line.
3、Compressor power supply must be equipped with isolating switch, in order to prevent the short
circuit resulting of default phase operation.
4、Check the secondary circuit fuse, and choose proper no wire safety switch according to the
compressor power watt level.
5、Our air compressor user power line size is in the list below.
Line size
Compressor
model.
HP/KW
voltage
（V）
frequency
（Hz）
maximum
current
（A）
line size
（mm2）
7.5/5.5
380
50
15
6
10/7.5
380
50
20
6
15/11
380
50
29
10
20/15
380
50
35
10

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6、The compressor should use a set of electric power systems alone, avoiding using
connect with the other different power consumption system, especially when the compressor
power is high, which may cause the compressor overload due to high voltage drop or three
phase current unbalance, making the protection device jump.
7、Connect ground line to prevent leakage danger. Do not connect to the air delivery pipe or cooling
water pipe!!!!!! (If the local regulation is stricter than the above requirements, follow the provisions of the
local.
b、Control system function
A series of BALDOR air compressor
1、start machine
When switch on, first, observe whether the power is in phase inversion. The machine has phase
sequence protection. If it is in phase inversion, the motor can't move. It can start again only adjusting phase
sequence. Press the \"start\" button on the panel, then the compressor will start with \"Y\" way and
working with “△” way.
Attention
It is strictly prohibited that the machine starts with load (exhaustion pressure shows pressure).
Otherwise it will damage the electrical components because of the large starting current.
2. Adjust load in the operation process
Control system has the automatic adjustment function. When the using air decreases, the
air pressure increases. If the pressure achieves the rated maximum, the control system will
send signals to the electromagnetic valve, controlling air inlet valve, make inlet valve close
30/22
380
50
50
16
40/30
380
50
67
25
50/37
380
50
86
35
70/55
380
50
128
60
100/75
380
50
165
80
125/90
380
50
179
125
150/110
380
50
217
150
175/132
380
50
242
185
220/160
380
50
292
240
270/200
380
50
348
300
340/250
380
50
433
400
430/315
380
50
544
400

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main engine air inlet. Thus, only little air can go into the main engine to ensure the system
lubricating oil pressure. At the same time, the relief valve in the electromagnetic valve or inlet
valve automatically opens, lowering the air pressure in oil-air separator, making the system
run with no-load. When the air pressure lows down to the rated limit, the control valve of the
system resets, and the machine operates in full load.
When the machine work in no-load, if the pressure does not drop to the rated limit in ten
minutes, system will automatically stop, and then the machine will be in standby mode.
3、stop machine
If need stop, please press “ON（I）” on the control panel. The machine will stop after unloading for a
period of time. There’s no “OFF” on the control panel, but urgent stop button. If need stop, please press the
urgent button when the machine is in unloading cases.
Only when the machine is abnormal condition, can press the urgent stop button, or else it will be
cause oil spitting phenomenon from the air inlet of air end!!!!!!
When the compressor is in abnormal situation (such as over temperature, over pressure, etc.), the
machine will automatically stop.
4、abnormal protection function
4.1 phase sequence protection
When the power line is in fault phase, it can't start. At this time, exchange any two inlet wire, and
restart.
4.2 exhaust temperature too high protection
The machine will automatically stop and alarm when the exhaust temperature reaches to the rated
temperature (generally 105 ℃). Panel will appear over temperature stop. There are many reasons causing
high exhaust temperature. The most common reason is that the oil cooler surface is covered by dust and
dirt, making oil cooling failure.
4.3 Over pressure of exhausting air protection
When exhaust pressure exceed the rated maximum pressure because of some reasons, the machine will
automatically stop and alarm and the panel will appear overpressure stop. Should check the reason, and
deal it properly.
4.4 overload protection
When the machine is overload because of some reasons, the machine will automatically stop and alarm
and the panel will appear overload stop. Should check the reason, and deal it properly.
4.5 Maintenance and alarm function (choose function)
There are alarm function and over pressure function. So if the machine is in these
situations: air filter plugging, oil filter plugging, oil-air separator core plugging, should do
corresponding processing.

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c、Attachment: (circuit)

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BALDOR AIR COMPRESSOR
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Chapter Five: Pipeline Configuration And
Installation
a. pipeline installing requirements
The machine air-supply port with screw thread adapter can connect with air-supply pipeline. Please refer
to the product appearance size when install.
1. When checking and maintenance, in order not to affect the overall or other machines work and
prevent air from flowing back, the stop valve should be installed between the machine and the storage
tank, and safety valve should be installed in the air storage tank.
2. Branch pipeline must connect from the top of the main line to avoid the condensed water flow back to
the compressor.
3. Shorten the pipeline and be straight linear delivery around the whole factory to reduce the bend and
all kinds of valve in order to reduce the pressure loss.
b. the general principles of the pipeline system
The pipeline system of compressing air should meet the users’ needs: compressed air flow rate,
pressure and air quality. And also determined from the other aspects: reliable air supply, saving energy,
reducing the investment, easy maintenance, etc. Specifically as below:
1. Consider from the pressure requirements
a、Pipeline system designed accord to meeting the customers’ needs of highest pressure. The other need
low pressure can install depressurized device on the local. Generally, common pressure of factory is 0.6
M Pa and 0.3 M Pa. The pipeline can fill 0.6 M Pa rated pressure, but install depressurized valve
behind the 0.3 M Pa pressure branch line valve to meet the requirements of low pressure customers’
needs.
b、Pipeline system can be divided into several pressure classes according to user's pressure size,
combined with the workshop or equipment arrangement, etc. Supply air by the several pressure class
of pipeline system.
2．consider the air quality
a、Use an untreated compressing air pipeline system. A few users who have special requirements of
air quality can install small device of oil removing, drying, and purifying in local.
b、Design two pipeline systems in the factory or some districts. One is for conveying untreated
compressed air, other for conveying dried or oil-free compressed air.
3．consider from the characteristics of the load
Some air equipment use air very different in instantaneous maximum air volume(such as the forging
hammers which use compressor power, mechanical workshop which use air power sending sand, pump and
large model, etc.). In order not to affect other air equipment, generally