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February 2016

Z-1454/2015
Pgs.36-Pos.70

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MEDICAL COMPRESSOR

DK50 DS

MANUFACTURER

EKOM spol. s r. o.
Priemyselná 5031/18
SK-921 01 Piešťany
Slovak Republic
tel.: +421 33 7967255
fax: +421 33 7967223

www.ekom.sk
email: ekom@ekom.sk

DATE OF LAST REVISION

02/2016

SM-DK50 DS-EN-20_02-2016

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CONTENTS

CONTENTS
1. GENERAL INFORMATION ............................................................................................ 2
PURPOSE ..............................................................................................................................................2
OPERATOR'S RESPONSIBILITY FOR PATIENT SAFETY .................................................................2
MARKINGS ............................................................................................................................................2
WARNINGS ...........................................................................................................................................2
General safety warnings .............................................................................................................3
Electrical system safety warnings ...............................................................................................3
WARNING NOTICES AND SYMBOLS..................................................................................................4
USE ........................................................................................................................................................5
STORAGE AND TRANSPORT ..............................................................................................................5
2. EQUIPMENT DESCRIPTION ......................................................................................... 6
3. TECHNICAL DATA ........................................................................................................ 8
4. OPERATION ................................................................................................................ 10
INSTALLATION AND FIRST OPERATION .........................................................................................10
Removal of transport stabilizers ...............................................................................................11
Wheel installation ......................................................................................................................11
Compressed air connection ......................................................................................................11
Electrical connection .................................................................................................................11
First operation ...........................................................................................................................12
Accessories...............................................................................................................................12
PERSONNEL .......................................................................................................................................13
Switching the compressor on....................................................................................................13
Running the compressor...........................................................................................................13
Cleaning and replacing the filters .............................................................................................15
Cleaning the compressor ..........................................................................................................15
5. MAINTENANCE ........................................................................................................... 16
REPAIRS AND SERVICE ....................................................................................................................16
Cover removal ..........................................................................................................................16
MAINTENANCE SCHEDULE ............................................................................................................16
Service interval signalization ....................................................................................................17
Service kit .................................................................................................................................17
Maintenance replacement parts ...............................................................................................18
Safety valve check ....................................................................................................................18
Check tightness of joints and inspect the equipment ...............................................................18
Replacing filters elements.........................................................................................................19
Output test, adjusting output pressure......................................................................................20
Cleaning the pressure regulator ...............................................................................................20
Replacing the inlet filter (21) .....................................................................................................20
Replacing the piston, connecting rod and piston rings .............................................................21
Replacing the bearing: ..............................................................................................................21
Control electronics - 115V version ............................................................................................22
Control electronics - 230V version ............................................................................................24
Stabilizing the compressor before shipping ..............................................................................28
SHUT-DOWN .......................................................................................................................................28
EQUIPMENT DISPOSAL .....................................................................................................................28
BATTERY DISPOSAL..........................................................................................................................28
6. TROUBLESHOOTING ................................................................................................. 29
7. SPARE PARTS ............................................................................................................ 30
8. ELECTRIC AND PNEUMATIC DIAGRAMS ................................................................ 31
WIRING DIAGRAM ..............................................................................................................................31
PNEUMATIC DIAGRAM ......................................................................................................................32
9. LIST OF SPARE PARTS ............................................................................................. 33

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GENERAL INFORMATION

1. GENERAL INFORMATION

PURPOSE

The EKOM DK50 DS is a medical air compressor that supplies clean, oil-free
compressed air for use with medical ventilators.

OPERATOR'S RESPONSIBILITY FOR PATIENT SAFETY

The Installation, Operation and Maintenance Manual is an integral part of the


equipment and must be kept with the compressor. Careful review of this
manual will provide information necessary for correct operation of the
equipment.

Rx only
US Federal law restricts the sale of this device by or on the order of a
physician.

MARKINGS

Products marked with the CE mark of compliance meet the safety


requirements of the European Union (93/42/EEC).

WARNINGS

 The safety of operating personnel and trouble-free operation of the


equipment are ensured only if original parts are used. Only accessories
and spare parts mentioned in the technical documentation or expressly
approved by the manufacturer can be used.
 If any other accessories or consumable materials are used, the
manufacturer cannot be held responsible for the safe operation and
functionality of the equipment.
 The warranty does not cover damages resulting from the use of
accessories or consumable materials other than those recommended by
the manufacturer.
 The manufacturer assumes responsibility for the safety, reliability and
function of the equipment only if:
- Installation, calibration, amendments, extensions and repairs are
performed by the manufacturer, one of its representatives or a service
provider authorized by the manufacturer
- The equipment is used in accordance with the Installation, Operation and
Maintenance Manual
 The Installation, Operation and Maintenance Manual accurately describes
the design of the compressor and its compliance with safety and technical
standards. The manufacturer reserves all rights to its wiring diagrams,
procedures and names.

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GENERAL INFORMATION

General safety warnings

The equipment is designed to operate safely when used correctly. Please


note the following safety measures to avoid injury or damage.

 Equipment operation must comply with all local codes and regulations.
 Original packaging should be kept for the possible return of the unit. Only
original packaging ensures optimal protection of the equipment during
transport. If it is necessary to return the equipment during the warranty
period, the manufacturer is not liable for damages caused by incorrect
packaging.
 The user must immediately notify the supplier if any problem occurs during
the use of the equipment.
 This product is not intended for use in areas where there is a risk of an
explosion. Do not operate the compressor in the presence of flammable
anesthetics.
 Never feed oxygen or nitrous oxide into the compressor. Compressor
components are not approved for oxygen or nitrous oxide use.

Electrical system safety warnings

 The equipment must be connected to ground. I order to assure proper


grounding, connect the compressor to a receptacle marked "hospital
grade."
 Before the compressor is plugged in, make sure that the voltage and
frequency of the mains specified on the equipment are the same as the
power mains.
 Before operating, check for possible damage to the equipment and any
connections. Damaged pneumatic and electrical lines must be replaced
immediately.
 If a technical failure occurs, immediately disconnect the equipment from
the mains (pull out the main power plug).
 During repairs and maintenance, ensure that:
- The main power plug is removed from the power socket
- Compressed air lines are disconnected
- All pressure has been released from the air tank
 Only a qualified technician can install this equipment.

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GENERAL INFORMATION

WARNING NOTICES AND SYMBOLS

The following symbols are used for important information in the Installation,
Operation and Maintenance Manual and on packaging and the product:

Attention, see instructions for use

Caution, risk of electric shock

Consult instructions for use

CE mark of compliance

Caution, hot surface

Handling mark on package – FRAGILE

Handling mark on package – THIS SIDE UP

Handling mark on package – KEEP DRY

Handling mark on package – TEMPERATURE LIMITATIONS

Handling mark on package – LIMITED STACKING

Mark on package – RECYCLABLE MATERIAL

Alternating current

Ground connection

Equipotentiality

Fuse

Condensate drain

Never dispose of the battery with common household waste.

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GENERAL INFORMATION

USE

 The equipment can be installed and operated only in a dry, ventilated and
dust-free area. Climatic conditions for operation - see Technical data.
 The compressor must stand on a flat and stable base.
 The compressor must not be exposed to rain. The equipment must not be
used in humid or wet environments. Never use the compressor in the
presence of flammable liquids or gases.
 Before connecting the compressor to respiration equipment, make sure
that it meets the requirements of the respiration equipment. Refer to the
Technical data for this purpose.
 Any use other than the compressor‘s intended use is not considered to be
safe. The manufacturer is not responsible for any damages that result if
the compressor is used for any other purpose. Risk is exclusively
assumed by the operator/user.

STORAGE AND TRANSPORT

The compressor is shipped from the factory in transport packaging with the
pump stabilized, protecting it from damage during transport.

For transport, always use the original packaging and secure the compressor
in the upright position.

Protect the compressor from humidity, contamination and extreme


temperatures during transport and storage. A compressor in its original
packaging should be stored in a warm, dry and dust-free area.

Keep the packaging material, if possible. If not, dispose of the packaging


material in an environmentally-friendly way. Cardboard can be recycled.

Before moving or transporting the compressor, the pressure in the air tank
and hoses must be released and any condensed water must be drained.
Secure the motor to prevent movement before shipping.

Prior to transport it is necessary to secure the motor inside the


compressor (Chapter 5.)

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EQUIPMENT DESCRIPTION

2. EQUIPMENT DESCRIPTION

1. Display – the primary display indicates outlet pressure


2. PRESSURE - alarm at low outlet pressure
3. TEMP - alarm at high operating temperature
4. DRYING – indicates drying level; yellow = unsatisfactory, green =
satisfactory
5. MAINS – loss of power alarm
6. TIME – hours of operation are displayed when the button is pressed
7. BATTERY – low battery indication = yellow
8. POWER – device status indicator = green
9. OUT – compressor outlet air
10. WALL - inlet air coming from an outside compressed air source
11. Main inlet, power switch, primary fuses
12. Equipotential (ground) pin
13. Socket for the electrical cord
14. Condensate tank
15. Air intake filter
16. Compressor
17. Safety valve
18. Air tank
19. a. Filter (40 μm) and water trap
19. b. Filter (5 μm) and water trap
20. Pressure regulator
21. Intake filter
22. Control electronics
23. Cooler

The compressor contains of an oil-free piston (16) driven by a low-maintenance single-


phase electric motor. Compressed air is cooled in the cooler (23) where condensed water
is separated into a separate tank (14). Incoming air passes through two filters (15, 21)
undergoing double filtration as it passes through the system (19). The model with a
membrane dryer is intended for applications that require a higher level of air dryness.
Constant outlet pressure is maintained by pressure regulator (20). The built-in air tank (18)
enables peak air consumption of 200 L/min.
The device may be used as a standby compressed air source. In this configuration, the
respiratory equipment is supplied with compressed air from the central compressed air
lines of the medical facility. Air pressure in the central compressed air line is monitored by
a pressure sensor. If the pressure is sufficient, the compressor stays in STANDBY mode.
If the pressure falls, the control unit automatically puts the compressor into operation.
When the compressor is used as the main source of air, the control unit determines its
operation according to the current demand for air. If air consumption is zero, the device
switches to STANDBY mode.
The compressor is equipped with indicators for outlet pressure (1), operating hours (6),
power status (8), drying status (4) and battery condition (7). Acoustic and optical alarms
activate to warn of high operating temperature (3), low outlet pressure (2) and loss of
power (5).

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EQUIPMENT DESCRIPTION

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TECHNICAL DATA

3. TECHNICAL DATA
TYPE DK50 DS
VERSION basic standard advanced
Outlet flow at pressure 3.5 bar (51 psig) Liters/min 40 50 60
Peak flow 200* L/min ( 7 Cft/min )
230/50 / 2.8
230/50 / 2.8 230/50 / 3.3
230/60 / 2.8
230/60 / 2.8 230/60 / 3.9
Voltage / Frequency / Nominal current V/Hz/A 120/60 / 5.6
120/60 / 5.6 120/60 / 6
120/60 / 5.6 UL model
100/50-60 / 5.6 100/50-60 / 6
100/50-60 / 5.6
Air filtration m 5
Pressure dew point at 40 L/min 5°C (9°F) below the ambient temperature
( 1.4 Cft/min), 3 bar( 43.5 psig ), 20°C (68°F) 10°C (18°F) with membrane dryer (optional)
DISS 1160-A (3/4"-16 UNF)
Outlet connection
optional NIST (EN 739)
50 50 51
Sound level dB(A)
51 / 60 Hz 51 / 60 Hz 52 / 60 Hz
Mode of operation Continuous - S1
Separation of condensed water Automatic
Yellow (working pressure < 4 bar (58 psig) )
Indication of drying
Green (working pressure ≥ 4 bar (58 psig) )
Low pressure alarm Decrease in outlet pressure under 2.1 bar ( 30.5 psig )
Cooling failure alarm Increase in internal temperature above 80°C (176°F)
3.0 bar (43 psig)
Outlet pressure
Adjustable to max. 3.5 bar (51 psig)
Decrease in pressure in the central air line under
Automatic start up pressure (backup)
2.8 bar ( 40.6 psig)
Air tank capacity 2 L (0.61gall UK)
Pressure range 5 bar ( 72.5 psig ) – 6.5 bar ( 94 psig)
Operating pressure of safety valve 7 bar ( 101.5 psig )
Adjustment of outlet air pressure Pressure regulator
Dimensions of compressor wxdxh 445 x 355 x 440 mm ( 17.5 x 14 x 17 in )
Dimensions of compressor with weels wxdxh 470 x 380 x 520 mm ( 18.5 x 15x 20.5 in )
Dimensions of compressor with trolley wxdxh 535 x 575 x 1054 mm ( 21 x 22,5 x 41.5 in )
Dimensions of packaging wxdxh 510 x 480 x 470 mm ( 20 x 19 x 18.5 in )
Dimensions of packaging 560 x 630 x 760 mm ( 22 x 25 x 30 in )
Net weight 34 kg ( 75 lbs )
Net weight of compressor with weels 36 kg ( 80 lbs )
Net weight of compressor with trolley 45 kg ( 99 lbs )
Gross weight 41 kg ( 91 lbs )
Gross weight of compressor with weels 43 kg ( 95 lbs )
Gross weight of compressor with trolley 60 kg ( 132 lbs )
Implementation according to EN 60601-1, EN 12021 Type B class I.
Classification acc. to MDD 93/42 EEC, 2007/47 EC II b
* With 0.6 bar pressure drop (8.7 psig)
Climatic conditions for storage and transport
Temperature –25°C to +55°C (-13°F to +131°F), 24 hrs +70°C (+158°F)
Relative air humidity 10% to 90 % (no condensation)
Relative air humidity for seaworthy packing 10% to 100% (with condensation)
Climatic conditions for operation
Temperature +15°C to +40°C (+59°F to +104°F)
Relative air humidity up to +95%
IPX0 Rating

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TECHNICAL DATA

FAD efficiency correction for differences in elevation

FAD correction table


2501 ‐ 3501 ‐
Elevation [mamsl] 0 ‐ 1500 1501 ‐ 2500
3500 4500
FAD [l/min] FAD x 1 FAD x 0.8 FAD x 0.71 FAD x 0.60
FAD efficiency refers to conditions at an elevation of 0 mamsl:

Temperature: 20°C
Atmospheric pressure: 101325 Pa
Relative humidity: 0%

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OPERATION

4. OPERATION

INSTALLATION AND FIRST OPERATION

Do not use the compressor immediately after unpacking as it will not


adjust to the ambient temperature.

Only qualified personnel can install the compressor and put it into
operation for the first time. The installer shall train the operating
personnel in the use and routine maintenance of the equipment.
Installation and training of personnel should be acknowledged by the
installer‘s signature on the installation certificate.

Prior to start-up, the four screws for transport stabilization must be


removed. If the compressor is switched on without removing the
stabilizers, the compressor could be permanently damaged.

The compressor does not contain a backup power supply.


Never block the air intake filter on the backside or the vent outlets on
the top of the equipment.
If the compressor is equipped with a main source of air, the standby air
source must be available.

ANY MODIFICATION OF THIS EQUIPMENT IS FORBIDDEN!

If this equipment is used nearby other instruments, the equipment must


be observed in order to verify normal operations in the configuration it
will be used.
Instruments may be affected electro-magnetically!

BEFORE FIRST USE REMOVE PROTECTIVE COVER OF THE SWITCH!

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OPERATION

Removal of transport stabilizers

On the bottom of the unit are four M6


stabilizing screws that must be removed
before start-up. They are marked with a
red warning washer.

Please retain the stabilizing screws for


future transport of the compressor.

Wheel installation

Wheels must be installed following the


figure below for versions of the
compressor with wheels.

Compressed air connection

The medical compressor is equipped with quick couplings WALL (10) and
OUT (9) on the rear of the cabinet.
Connect the pressure hose from the given equipment/respiration equipment
to the quick coupling OUT (9) -outlet compressed air.
Connect the compressed air line from the central distribution line o the quick
coupling WALL (10) -inlet compressed air. Air from the distribution system is
automatically connected through the compressor to the OUT outlet port. In
this configuration, the compressor serves as a backup source of compressed
air. If the air pressure from the central distribution system is reduced, the
compressor automatically switches on and there is no interruption in the
supply of continuously pressurized air at the outlet of the compressor.

Please note that the air supply from the central distribution line
entering the compressor must be medical grade air (particulate size,
humidity.) The compressor does not modify the air from the central
distribution line.

The hose connecting the compressor to the respiration equipment


must not pass through a cold environment i.e. placed on the ground. It
should be as short as possible with no kinks (this may cause water to
condense inside the hose).

Electrical connection

The compressor comes with a plug containing an appropriate


protective contact (ground.) Adhere to local electrical regulations. The

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OPERATION

voltage and frequency of the mains must comply with the


specifications on the data label.

The electrical cord must not be stressed or have any tension exerted
upon it, and must always be free.

 The socket must be accessible for safety reasons so that the equipment
can be safely disconnected from the power supply in case of an
emergency.
 The relevant current circuit must be protected.
 Connection of the ground connection (12) to other equipment must adhere
to local electrical regulations.
 Fasten the electrical cord through the holder (13).

First operation

 Make sure that the stabilizing screws used during transport were
removed.
 Check that the connection to the compressed air supply is correct.
 Check for proper connection to the main power supply.
 Switch on the pressure switch (11) to position “I”.

After the compressor is put into operation, it shall work in one of the following
modes depending upon the pressure level in the central distribution and upon
air consumption.
 STANDBY – When there is sufficient pressure in the central air distribution
line, the main switch is on and the POWER (8) indicator is on, the
compressor is idle. The device operates as a standby source of air as it
checks the pressure in the central air distribution line and, if the pressure
falls, the compressor switches on.
 When pressure is low in the central air distribution line, or if the device is
not connected to the central distribution line, the compressor is running. If
there is no air consumption at the outlet, the device switches to STANDBY
mode. When air consumption resumes, the compressor automatically
switches on.
 The working pressure in the air tank when the compressor is running is
maintained between the high and low pressure limits by the control unit.
After the high working pressure limit is reached, the compressor output is
connected to the exhaust (bypass) and the compressor stops supplying
compressed air to the air tank until as long as the pressure in the tank does
not drop below the low pressure limit.
During operation, the device drains the trapped condensed water from
pneumatic circuits via automatic filter separators into a separate tank.

Accessories

Trolley SD 30 (24)

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OPERATION

The trolley accommodates the compressor, a fan and a humidifier. Large


casters allow for mobility and braking, guided by means of an ergonomic
handle. A wide base ensures the stability of the entire assembly.

Specifications
Supply No.: 602021222
Dimensions: 535x575x1070
Maximal load-carrying capacity with load
in the upper plate axis (1):
Trolley without compressor - 25kg
Trolley with compressor - 30kg

The manufacturer is not liable for any damage


resulting from excessive loads on the equipment!
The supplier is obliged to ensure the acceptability of a load delivered
by a supplied accessory.
It is forbidden to lean or press against an installed accessory for
support!
The equipment must be lifted when travelling over an obstacle!
Supporting equipment must be disassemble before transport!

The maximum load on the upper trolley plate is 30 kg!

Humidifier holder (25)


This clamp is used to attach the Fischer & Paykel humidifier to the trolley in
its proper position.
Supply No. 604031175

PERSONNEL

In case of emergency, switch the equipment off at the switch and pull
out the main power plug.

Switching the compressor on

The compressor is switched on at the main power switch (11) by putting it in


position "I". Switching on is signaled by the green indicator (8).

Running the compressor

The green indicator POWER (8) is lit up during operation. The display shows
the value of outlet pressure with accuracy ± 5% in BAR or PSI units. An
indicator is lit on the display next to the relevant unit. Ask the service staff
member to change the units that are shown if necessary.

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OPERATION

115V version -
After pressing the TIME (6) button, the display shows the number of hours in
operation.
230V version -
After pressing the TIME (6) button, the display shows the number of hours in
operation. The compressor operating hours since the last service work are
displayed by pressing the button for about 2 seconds.

The calculated running interval is set to a coefficient of 1.0 if the compressor


is supplying compressed air to the air tank. The calculated coefficient is 0.3
in “BYPASS” mode. The DRYING (4) indicator displays the drying status.
Green indicates satisfactory drying; yellow indicates unsatisfactory drying. If
the yellow indicator DRYING (4) stays on, make sure that air consumption
from the compressor does not exceed outlet flow according to specification. If
air consumption is within normal parameters, contact a service centre.

A decrease in outlet pressure is indicated by the alarm PRESSURE (2) which


sounds an alarm and illuminates the yellow indicator. The alarm is activated
if the outlet pressure does not reach the required level and in the interval
after the compressor is turned on until it reaches the required pressure. If the
alarm stays on, make sure that the air consumption does not exceed outlet
flow according to specification. If air consumption is within normal
parameters, contact a service centre.

A cooling failure is indicated by the alarm TEMP (3) which sounds an alarm
and illuminates the yellow indicator. The device must be immediately
disconnected from the electrical mains and cooled down. Cooling failure
activation may indicate that the vent holes were covered, the filter in the
bottom part of the compressor is contaminated or the compressor is in
environment with higher temperature. If none of these circumstances apply,
a malfunction has occurred and service is required.

The alarm MAINS (5) is activated upon the interruption in the power supply to
the compressor.

Illumination of the yellow indicator BATTERY (7) indicates a low battery. The
battery is charged automatically during equipment operation. If the yellow
control light does not turn off after 24 hours of the equipment operation, it is
necessary to change the battery. The battery powers the MAINS (5) alarm
and has no impact on other functions of the device. Entrust an authorized
service provider with its replacement. Replace the battery with an identical
replacement - NiMH 9V 200mAh.

Used batteries cannot be disposed of as household waste, they must be


collected separately.

The condensed liquid drains into a separate tank (14) at the back of the
equipment. When the tank fills up, it must be emptied.

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OPERATION

Close the plug located on the neck of the vessel before moving any
vessel containing a liquid!

Cleaning and replacing the filters

At least once a week take out and clean the suction filter (15) located on the
back side. Wash the filter in warm soapy water, rinse thoroughly and allow it
to dry. Insert the clean filters so that the intake openings are completely
covered by the filters.

Cleaning the compressor

To clean the compressor, use a detergent that contains no abrasives,


chemical solvents or other corrosive agents.

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MAINTENANCE

5. MAINTENANCE

REPAIRS AND SERVICE

Warranty and extended warranty repairs are to be completed by the


manufacturer or a service provider authorized by the manufacturer.

The manufacturer reserves the right to modify the equipment in any


way that will not alter the function or the operation of the equipment.

Only a qualified technician or the Customer Service Department of the


manufacturer may perform repairs that go beyond routine maintenance.
Use only spare parts and accessories approved by the manufacturer.

Prior to any maintenance or repairs, switch off the compressor and


disconnect it from the mains (pull out the main power plug).

Cover removal

- Unscrew the 6 screws from the rear cover


- Disconnect the grounding wire
- Remove the rear cover
- Disconnect the wiring connector for the display and pull the wiring out from
the opening in the frame
- Unscrew the 4 screws from the rear of the main cover and 2 screws from
the rear part of the rail
- Disconnect the grounding wire
- Remove the main cover
- Reassemble using the opposite order

MAINTENANCE SCHEDULE

Time interval (Hour)


Maintenance Page
4000 8000
Safety valve check 17 1 x per year
Test the tightness of joints and
17 after two years
inspect the equipment
Replace service kit A (filters) 18 x x
Replace service kit B 19-21 X*
*) – The suction filter replacement interval must be shortened accordingly if
used in a dusty or dirty environment!

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MAINTENANCE

Service interval signalization

Once 4000 operating hours have been reached, the value “4000” starts to
appear as the outlet pressure from the equipment, alternating with the actual
outlet pressure value. They alternate about every 2 seconds. Once this
information appears, the operator is obliged to secure service work for the
equipment.
After completing the service work, the service technician will zero out this
counter as follows:

115V version -
- Switch off the equipment (switching from I → 0 or by disconnecting the
power)
- Moving the jumper for the bar – psi outlet pressure into a different position
(the procedure is shown in the page 23)
- Switch on the equipment (switching from 0 → I or by connecting the power)
- Switch off the equipment (switching from I → 0 or by disconnecting the
power)
- Moving the jumper for the bar – psi outlet pressure back into its original
position
- Switch on the equipment (switching from 0 → I or by connecting the power)
This operation resets the internal service interval counter to zero.

230V version -
The shorted “Service Display” jumper can be used to zero-out the service
hours. After the shorted “Display PSI” jumper is inserted and removed or
removed and inserted, the service hour counter is set to zero. Use the same
method for setting the motor hours if the service hour counter needs to be set
(the procedure is shown in the page 26).

Service kit
Type DK50 DS Part No. 604041077-000

A
4000 hrs. Input filter Filter Filter
Type 4KC-500 40 µm 5 µm
Number 025000018-000 025200142-000 025200113-000
pc 1 1 1

typ DK50 DS basic, standard 230V Part No. 604041078-000


typ DK50 DS basic, standard 100-120V Part No. 604041079-000
typ DK50 DS advanced 230V/ 50Hz Part No. 604041091-000
typ DK50 DS advanced 100-120V Part No. 604041092-000

B
Piston with Filter coverSolenoid
8000 hrs . Suction filter O-ring Bearing Hose
rod complete
according to bubble to according to
Type 05W D50x2 6204 2RS DN8x400
model AF20,AW20 model
025200194 073000109 024000881- 025900018- 072000009-
Number
-000 -000 000 000 000
pc 1 1 2 1 2 1 1

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MAINTENANCE

Maintenance replacement parts

When performing routine service, the manufacturer recommends the


following replacement parts that may be ordered separately:

 Cylinder fitting Part No. 023000239-000


 Bearing removeal tool 6204 Part No. 604001094-000
 Pressure gauge set Part No. 191000007-000
 Hose with valve Part No. 191000008-000
 Flow meter set Part No. 191000009-000

Safety valve check

The safety valve is adjusted to 7 bar by the manufacturer, then tested


and marked. It must not be readjusted!

 Only allow the safety valve freely


puff for a short period of time.

Never use the safety valve to release pressure in the air tank. This could
damage the safety valve.

Check tightness of joints and inspect the equipment

Test for leakage:


 Disconnect the outlet hose from the quick coupling OUT (9); compressed
air consumption will stop.
 Pressurize the air tank by releasing some air via a connected device.
 With the compressor off, wait at least 10 minutes before checking the
pressure level.
 If the pressure has dropped, use soapy water to find the leaky joint. Start
with the joints outside the case, and then test the ones inside the case
after removing the covers.
 Tighten or re-seal joints as necessary.

Inspect the equipment:


 Clean and vacuum the interior of the cabinet.
 Check the status of the compressor motor for balanced operation or noise.
 Check the condition of the hangers above the pump.
 Check fan functionality.

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MAINTENANCE

 Check the condition of the filter. With regular operation, condensate from
the filter (19) drains automatically. Verify this function by comparing the
level of condensate in the bottle to the scale line indicating the maximum
level. If the level of condensate is above the scale line, replace the faulty
parts.
 Examine the pump for:
- Defects in the crankcase
- Free movement of the crank shaft
 If necessary, replace any faulty parts.

Replacing filters elements

Before beginning, evacuate all compressed air from the tank, reducing
the tank pressure to zero and disconnect the equipment from the power
mains.

 Unscrew the cover and pull it out using the enclosed wrench (26).
 Unscrew the filter holder.
 Replace the filter and screw the filter holder
into place.
 Screw the cover back in place. 26

Spare filtration pads:


Bronze (40 μm) (19a) AF20P-060S-7-40B Item 025200142
Plastic (5 μm) (19b) AF20P-060S Item 025200113

If the water release system becomes clogged, disassemble the release valve
(f), clean the outlet, remove the float (b) with a lever mechanism (c, d, and e)
from the tank, clean all components with a soap solution and then
reassemble.

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MAINTENANCE

Output test, adjusting output pressure

 Connect the hose with valve and flow meter (flow meter
set) to the connection port marked OUT.
 Pull up the control knob on the regulator (20) and rotate
clockwise until it reaches the stop.
 Switch on the the compressor. Turn the valve on the hose
to set the pressure on the compressor pressure gauge
(display) to 5 bar.
 Check compressor output using the gradations on the flow
meter.
 Rotate the control knob on the regulator (20) to bring the
output pressure on the compressor pressure gauge
(display) to 3 bar.
 Press down the control knob on the regulator to lock in the
regulator setting.

Cleaning the pressure regulator

 Set the pressure to the minimum position


 Remove the plug (1)
 Rotate and remove the latch (2)
 Remove the line from the valve (3) and
the valve (4), then clean the valve seat
and the o-ring
 Re-install the components in the
following order: (4), (3), (2) and (1)

Replacing the inlet filter (21)

 Unlock the cover and pull it out.


 Replace the filter
 Lock the cover

Spare part:
Intake filter 05W POLYESTER, Item 025200194

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MAINTENANCE

Replacing the piston, connecting rod and piston rings

 Disconnect the pressure hose (1).


 Remove the crankcase cover (2) and pull off the cylinder head (3).
Disassemble the spring (4) and valve plate (5) with O-rings (6) (2 pcs) and
carefully remove the cylinder (7).
 Remove the screw (8) on the piston’s connecting rod (9), eject the
connecting rod from the bearing (10) and take it out.
 Install the new connecting rod with the piston on the bearing (around
11.5 mm from the crank), install the cylinder (7) and secure using
compound with item no. 023000239 (12) and 2 bolts; then rotate the crank
a number of times (at least 10 times), check the position of the connecting
rod in the piston (11) and adjust the torque applied on the connecting rod
bolt (8) to a torque of 2.5 Nm + 0.5 Nm. If the connecting rod is not
positioned correctly, reposition the connecting rod on the bearing and
tighten the screw on the connecting rod.
 Remove the cylinder fitting and place the cylinder onto the crankcase.
Assemble the valve plate (5) with O-rings (6) (2 pcs) and spring (4). Cover
with the cylinder head (3) and secure it with the screws (4 pcs) with
washers (4 pcs).
 Turn the crank several times to ensure that the connecting rod moves
smoothly. Attach the crankcase cover (2) using screws (6 pcs). Connect
the pressure hose.

Replacing the bearing:

Disassembly

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MAINTENANCE

 Remove the bearing using the bearing 6204 removal tool (Part No.
604001094).

 If the bearing is damaged and missing its external ring, use the metal ring
together with the clamping sleeve.
 Put the clamping sleeve and the metal ring on the internal ring. Tighten
the clamp.

Assembly

 Secure the crank against movement.


 Screw on the draw rod of the bearing pressing set.
 Place the new bearing on the draw rod, fix the guide extension with a
washer and screw on the tightening nut to completely seat the bearing.

Control electronics - 115V version

Procedure for replacing the SMART circuit board

Handling the printed circuit board

- Protect against a static electricity discharge when handling


- The battery cannot be mounted on the printed circuit board before the board
is installed
- Mount the battery after the printed circuit board has been installed and
check to ensure polarity is correct
 If possible mark down the value of the operating hours counter
 Safely disconnect the power from the equipment
 Remove the rear panel from the compressor
 Disconnect the hoses, connector and wires from the printed circuit board
 Remove the printed circuit board and replace with a new one
 Reconnect the wires and connector following the electrical schematic

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MAINTENANCE

Procedure for entering operating hours into the new circuit board:

A computer or laptop, RS232 SMART SERVICE cable and Serv_Smart WH


v.2.0.1 software are necessary to complete this work. Install the software by
running “Setup.exe” and then proceed following the prompts that are
displayed. Run the “Ssmartwh.exe” file once the program has been installed.
Then proceed as follows:

 Connect the compressor to the computer using the “RS232 SMART


SERVICE” cable.
 Run the “Serv_Smart WH v.2.0.1” program
 Select the proper port number in the PC
 Connect power to the equipment and turn on the main switch
 Confirm “Set”
 Enter the value recorded for operating hours and confirm with “OK”
 Close the program, switch off the equipment, disconnect the “RS232
SMART SERVICE” cable from the equipment and reinstall the rear cover
 The compressor is ready for additional use

When handling exposed parts of the equipment that are energized, be


careful to avoid contact with energized components (wire connections,
the circuit board, circuit board cooler, etc.).

If necessary to repeat this procedure, a counter value that is lower than


the previous value cannot be entered!

SMART electronics works in the following modes:


 STANDBY, if the compressor is without air intake, working pressure is
almost minimal, output pressure is nominal – the engine is halted and
solenoid valve is without voltage. Just POWER lamp is on and display of
output pressure displays output pressure.
 FULL POWER, if working pressure was lower than 5.0 bar and it has not
reached 6.5 bar yet – the engine is working, solenoid valve is connected
to voltage. Complete indication.
 SMART, if working pressure has reached 6.5 bar and now it is lower than
6.5 bar and greater than 5.0 bar, non-zero air intake is from compressor
outlet – the engine works but solenoid valve is without voltage. Complete
indication.

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MAINTENANCE

Conversion of Physical Units bar – psi


The control electronics has the feature for the conversion of display of output
pressure from physical units “bar” to “psi”. Conversion is to be carried out
using “JM1” jumper (bar - 1,2) (psi - 2,3) that is set by manufacturer in
“bar” position. Indication of setup is displayed on the display as follows:

 Bar – horizontal line on top


 Psi – horizontal line in the centre

1 2 3

Control electronics - 230V version

Equipment function in operating mode


All the segments and the LEDs will light after power is connected; also the
buzzer will chirp.

The program version will be displayed shortly thereafter.

The display will then show the outlet pressure in the units defined by the
"Display PSI" jumper. The jumper position is clear from the positioning of

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MAINTENANCE

RSK10 components in Fig. 1. The “Service Display” and “Calibration Jumper”


jumpers are disconnected.
Outlet pressure in bar (“PSI” jumper disconnected)

Outlet pressure in PSI (“PSI” jumper shorted)

Motor hour set up


RSK10 layout – component side

Calibration jumper Service Display

Display PSI
Fig. 1 – Positioning of RSK10 components

If the number of compressor motor hours since the previous service work
exceeds 4000, the value “4000” will alternate with the outlet pressure on the
screen at a 2 second interval. This indicates the need for a service inspection
of the compressor.
The display will show the hours on the compressor motor once pressed.

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MAINTENANCE

The compressor motor hours since the last service work will be displayed by
pressing the button for about 2 seconds.

If the button is held in, this information will alternate on the display at a 2
second interval. The outlet pressure in the selected units is shown once the
button is released. The appropriate segment of the final display digit will light
up, indicating the displayed unit.

LED signalization

 “PRESSURE” alarm – yellow LED + acoustic signal – if outlet p2 pressure


drops ≤ 2.0bar
 “TEMP” alarm – yellow LED + acoustic signal – if T1 temperature is ≥ 80 ˚C
 “MAINS” alarm – yellow LED + acoustic signal – if power source to the unit
drops below 10V and main switch is closed (X9 and X10 are connected).
 “BATTERY” alarm – yellow LED if battery voltage drops below 8V
 “DRYING” indicator – measurement of P1 pressure, green LED – P1 ≥ 4
bar, yellow LED – P1 < 4 bar
 “POWER” indicator – green LED
 Pressure unit indicator (horizontal mark shown on display) – for bar or psi –
the circuit board jumper can be switched to change the displayed pressure
from bar or psi

Service display

The unit includes a “Service Display” jumper in order to ease access to


parameter measurements and diagnostics. The jumper position is clear from
the positioning of RSK10 components in Fig. 1.
Pressing the button alternates between the information displayed. The right
edge of the display indicates the data shown. Data displayed after jumping
the XP3 pins to the “Service Display” position:

P1 working pressure in bar

P2 outlet pressure in bar

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MAINTENANCE

Temperature in ˚C

Battery voltage without charging

Charging battery voltage; charging is indicated by the lit decimal point.

Voltage to control electronics

Motor hours

If the motor hour counter needs to be set, for example the compressor control
unit is replaced, the “Service Display” jumper must be shorted. After the
appropriate pins are shorted on the XP2 connector (Fig. 1) using the jumper,
the motor hour counter value will count up. Remove the jumper once the
desired number of hours is shown.
Motor minutes

Service hours

The shorted “Service Display” jumper can be used to zero-out the service
hours. After the shorted “Display PSI” jumper is inserted and removed or
removed and inserted, the service hour counter is set to zero. Use the same
method for setting the motor hours if the service hour counter needs to be
set.

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MAINTENANCE

The pressure sensor must be checked when any service work is completed
on the unit; if water is present, blow out with compressed air and dry it out.
The long-term presence of water in the sensor can destroy the sensor. After
regular service work is completed, the service hour counter must be zeroed
out using the procedure described in the “Service Display” chapter.

Stabilizing the compressor before shipping

Before shipping, the compressor must


be stabilized to prevent movement.
Prior to fixation, it is necessary to
disassemble the plastic cover. The air
pump must be fixed to the base using
the four original M6 screws (see
picture). Assemble the plastic cover.

SHUT-DOWN

If the compressor is not going to be used for a long period of time,


disconnected it from the main power supply and release the pressure in the
air tank.

EQUIPMENT DISPOSAL

 Disconnect the equipment from the main power supply.


 Release the pressure in the air tank.
 Dispose of the equipment according to local regulations.
 Parts used in this product have no negative impact on the environment
when disposed of properly.

BATTERY DISPOSAL

No battery may be disposed with common household waste. Dispose of


non-functional batteries at suitable collection sites.

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TROUBLESHOOTING

6. TROUBLESHOOTING

Prior to servicing the equipment, reduce the pressure in the air tank to
zero and disconnect the equipment from the main power supply.

Only trained service personnel can perform the activities listed in the
troubleshooting guide.

PROBLEM POTENTIAL CAUSE SOLVING COMMON PROBLEMS


In STANDBY mode, the compressor starts
There is pressure in the air tank
when pressure decreases
Switched off main breaker in distribution system
Check supply
No main power voltage
Replace a defective fuse
Compressor does Loose wire terminal – tighten
not start
Power cord defective – replace
Interrupted winding of motor, damaged
Replace motor
thermal protection
Defective capacitor Replace capacitor
Jammed piston or other part Replace damaged parts
Leakage of air from pneumatic Inspect pneumatic distribution system – seal
distribution system loose connection
DRYING indicator Large consumption of compressed air Do not exceed max. flow (see Technical data)
lights yellow Worn out piston rings Replace worn out piston rings
permanently
Dirty air suction filter Replace the dirty air suction filter
Dirty air intake filter Clean or replace the dirty air intake filter
Leakage of air from pneumatic Inspect the pneumatic distribution system –
distribution system seal loose connection
Large consumption of compressed air Do not exceed max. flow (see Technical data)
PRESSURE
alarm is activated Worn out piston rings Replace worn out piston rings
permanently Dirty air suction filter Replace the dirty air suction filter
Dirty air intake filter Clean or replace the dirty air intake filter
Dirty filter inserts of filter Replace the dirty inserts
Dirty air blow down filter Clean or replace the dirty air blow down filter
TEMP alarm is Covered vent holes Uncover vent holes
activated Cooling fans don’t work Replace fans
Unit is hot, unventilated area Relocate unit
Damaged piston bearing or bearing in
Compressor is Replace damaged bearing
motor
noisy (knocking,
Loose (cracked) belt of the air pump
metal noises) Replace damaged hanger
hanger
Water coming out Dirty water trap in filter and filter
Clean or replace the water trap
of outlets regulator
Compressor
Failure of control unit Adjust using service software
malfunction

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SPARE PARTS

7. SPARE PARTS

 Air intake filter (15 ) 025000018-000


 Filtration inserts (19a) 025200142-000
 Filtration inserts (19b) 025200113-000
 Fuse
version 230V T6,3A 038100004-000
100V, 120V T10A 038100005-000
 Insertion DISS 1160-A 024000261-000
 Suction filter 05W POLYESTER 025200194-000

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ELECTRIC AND PNEUMATIC DIAGRAMS

8. ELECTRIC AND PNEUMATIC DIAGRAMS

WIRING DIAGRAM

1/N/PE ~ 230/120/100 V 50..60 Hz


ELECTRIC OBJECT OF 1st CAT.
B TYPE

DISPLAY
YV ST
?

14

1 X2
14
U Display
Valve
N

N - +

N
9V
N
battery
U ~
U Motor
U Fan

3rd contact

X1

M
XC 1
M EV1 EV2

U PE N
Wiring diagram DK50 DS

Mark Name Mark Name


X1, X2 Sockets on PCB M Electric motor
EV1, EV2 Fan ST Thermal sensor
YV Solenoid valve XC Socket with fuses
Q Switch

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ELECTRIC AND PNEUMATIC DIAGRAMS

PNEUMATIC DIAGRAM

4 10 11
8
OUT

T1 9
6 7 6
3 2 WALL

5 12
P1 P2

1. Suction filter
2. Compressor
3. Solenoid valve
4. Return valve
5. Cooler
6. Filter with water trap
7. Pressure regulator
8. Air outlet
9. Air inlet
10. Air tank
11. Safety valve
12. Shuttle valve

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LIST OF SPARE PARTS

9. LIST OF SPARE PARTS

230V/50Hz 603011741-000 230V/50Hz 603011883-000


230V/60Hz 603011825-000 Air pump DK50 DS 230V/60Hz 603012258-000
Air pump DK50 DS
115V/60Hz 603011826-000 Model advanced 115V/60Hz 603011957-000
Model basic
100V/50-60Hz 603011827-000 100V/50-60Hz 603011958-000
120/60Hz UL 603012084-000
230V/50Hz 603011918-000
Air pump DK50 DS 230V/60Hz 603011741-000
Model standard 115V/60Hz 603011959-000
100V/50-60Hz 603011956-000
1 Screw M6x90 041000530-000 17 Screw M8x16 041000051-000
2 Washer 6 043000007-000 18 Crank case
3 Cylinder head compl. 4DA-119 604031119-000 Model basic, standard
4 Spring II 4KA-019 022000010-000 Model advanced 115/60,230/60 024001273-000
5 O-ring 50x2 073000109-000 Model advanced 100/50-60,230/50
6 Valve plate 4CA-023 604021023-000 19 Screw M6x25 041000501-000
7 Cylinder 20 Ledge 4KC-665 023000911-000
Model basic 21 Washer 6,4 043000010-000
Model advanced 050000049-000 22 Washer 6 043000007-000
Model standard 230/60 23 Nut M6 042000005-000
Model basic UL 050000073-000 24 motor
Model standard 100/50-60,230/50 1LF9073-4AJ99-ZN58 230V/50Hz 035110010-000
050000063-000
115/60 230V/60Hz
8 Washer - Capacitor 16 MF 031330007-000
Model basic 115/60, 230/60 Motor
Model advanced 230/50, 230/60, 1LF9073-4AJ99-ZN60 230V/50Hz – 035110057-000
024001190-000
115/60, 100/50- ADVAN
60 230V/60Hz-ADV
9 Piston with piston rod - Capacitor 18 MF
Model basic, standard 604021396-000 motor
Model basic UL 604021372-000 1LF9073-4AJ99-ZN60 115V/60Hz 035110013-000
Model advanced 100/50-60,230/50 604021372-000 - Capacitor 60MF/250V 031330034-000
10 Piston ring 069000123-000 motor - UL
11 Screw IMB M6x25 041000115-000 1LF9073-4AJ99-ZN26 120V/60Hz 035110034-000
12 Crank case cap 3KC-404 050000050-000 - Capacitor MLR25, 031330036-000
60MF/250V
13 Screw M4x10 041000110-000 motor
14 Fiting G1/4 MF 024000948-000 1LF9073-4AJ99-ZN61 100V/50-60Hz 035110019-000
15 Bearing 6204 024000881-000 - Capacitor
16 Crank 25 Fiting G3/8 024000324-000
Model basic, standard Fitting 26 Fiting 025400034-000
Model basic UL 120V/60Hz 604031474-000 27 Plug 062000803-000
Model advanced 230/50 604031165-000 28 Retaining ring 049000209-000
Model advanced 115V/60Hz 604031405-000
100/50-60,230/60

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LIST OF SPARE PARTS

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LIST OF SPARE PARTS

Compressor DK50 DS

27 Bottle cap 4KB-956 062000350-000 45 Air pump compl.


28 Bottle LUH-1 062000333-000 Model basic 230V/50Hz 603011741-000
29 Check valve 3/8" MF 025300026-000 230V/60Hz 603011825-000
30 Foam 061000285-000 115V/60Hz 603011826-000
31 Fan 230V/50-60Hz 035300006-000 100V/50-60Hz 603011827-000
115V/60Hz 035300005-000 120/60Hz UL 603012084-000
32 Hanger 4BA-779 604011779-000 Model standard 230V/50Hz 603011918-000
33 Foam 061000284-000 230V/60Hz 603011741-000
34 Screwing 025500161-000 115V/60Hz 603011959-000
35 Frame 3DA-099 603031099-000 100V/50-60Hz 603011956-000
36 Hanger 4BA-947 604011947-000 Model advanced 230V/50Hz 603011883-000
37 Solenoid valve compl. 230V 603011740-000 230V/60Hz 603012258-000
115V,100 V 603011828-000 115V/60Hz 603011957-000
100V/50-60Hz 603011958-000
38 Angular screwing 025500238-000
39 Reduction 025400163-000
40 Fiting T 8-1/4 025400231-000
41 Fiting L G1/8 M/F 025400020-000
42 Hose D8x400 072000009-000 a Hose PA 8/6 blue 072000048-000
43 Safety valve 025300058-000 b Hose PA 6/4 neutral 072000026-000
Safety valve UL 025300069-000 c Hose PU 6x4x1 black 072000030-000
44 Insertion 024000947-000

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LIST OF SPARE PARTS

Compressor DK50 DS

46 Shuttle valve 025300082-000 66 Fastener 029000122-000


47 Angular screwing L 8/6-1/4" 025500122-000 67 Angular screwing 025500193-000
48 Coupling G1/4 FF 024000947-000 68 Block of filters complete 604021730-000
49 Switch 033500025-000 69 Elektronic 230V 035900085-000
Switch UL 033500032-000 - control module, batery 230V 035900108-000
50 Connector 033200060-000 - keyboard 035900109-000
51 Quick-acting coupling with valve4KB-494 024000492-000 Elektronic 115V,100V 035900060-000
120V
52 Pin for mains connection 024000364-000 - control module, batery 035900107-000
- keyboard 035900055-000
53 Fuse holder 033200061-000 - cable RS232 034140019-000
54 Quick-acting coupling without 4KB-493 024000493-000 - SW 2.0.1 039100002-000
valve
55 Cooler complete 4CA-250 604021250-000 70 Block of filters 025900028-000
56 Rubber leg 074000123-000 - filter 40 µm 025200284-000
57 Screw 041000702-000 - regulator 025200219-000
58 Fitting 6 025500236-000 - filter 5 µm 025200178-000
59 Coupling 6/4 025400154-000 - adapter 2x 025400164-000
60 Angular screwing 025400153-000 71 Screwing 025500193-000
61 Coupling T 6x4 025400041-000 72 Coupling 025400239-000
62 Bumper 029000130-000 73 Screwing 025400162-000
63 Fastener 029000121-000 74 Screwing 025500161-000
64 Wheel 029000119-000 75 Filter silencers FS-05-025 025200115-000
65 Wheel braking 029000120-000 - Suction filter 025200194-000

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LIST OF SPARE PARTS

Compressor DK50 DS

76 Cover complete 3BB-046 603012046-000 80 Foam 4 4KC-505 061000287-000


81 Foam 3 4KC-504 061000286-000
77 Cover 603021565-000 82 Cover back complete 3CA-339 603021339-000
Cover UL 062000676-000 83 Foam 6 4KC-678 061000301-000
78 Display cover 4KD-560 062000672-000 84 Cover back 3DA-098 603031098-000
79 Ledge 4DA-083 604031083-000 85 Filter 4KC-500 025000018-000

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