AUGUST 2012

Z/701-2012 From serial numbers: A2313-5-2012

(page 31 - pos.37, page 33 - pos.76 )
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: [email protected]

DATE OF LAST REVISION

08/2012

SM-DK50 DS-GB-11_08-2012
CONTENTS

CONTENTS
1.  GENERAL INFORMATION ........................................................................................... 1 
PURPOSE ............................................................................................................................................. 1 
OPERATOR'S RESPONSIBILITY FOR PATIENT SAFETY ................................................................ 1 
MARKINGS ........................................................................................................................................... 1 
WARNINGS ........................................................................................................................................... 1 
General safety warnings ............................................................................................................ 2 
Electrical system safety warnings .............................................................................................. 2 
WARNING NOTICES AND SYMBOLS ................................................................................................. 3 
USE ....................................................................................................................................................... 4 
STORAGE AND TRANSPORT ............................................................................................................. 4 
2.  EQUIPMENT DESCRIPTION ........................................................................................ 5 
3.  TECHNICAL DATA ....................................................................................................... 7 
4.  OPERATION.................................................................................................................. 8 
INSTALLATION AND FIRST OPERATION .......................................................................................... 8 
Removal of transport stabilizers ................................................................................................. 8 
Wheel installation ....................................................................................................................... 8 
Compressed air connection ....................................................................................................... 9 
Electrical connection .................................................................................................................. 9 
First operation ............................................................................................................................ 9 
Accessories .............................................................................................................................. 10 
PERSONNEL ...................................................................................................................................... 11 
Switching the compressor on ................................................................................................... 11 
Running the compressor .......................................................................................................... 11 
Cleaning and replacing the filters............................................................................................. 12 
Cleaning the compressor ......................................................................................................... 12 
5.  MAINTENANCE .......................................................................................................... 13 
REPAIRS AND SERVICE ................................................................................................................... 13 
Cover removal .......................................................................................................................... 13 
MAINTENANCE SCHEDULE............................................................................................................ 13 
Service interval signalization.................................................................................................... 14 
Service kit................................................................................................................................. 14 
Maintenance replacement parts............................................................................................... 15 
Safety valve check ................................................................................................................... 15 
Check tightness of joints and inspect the equipment............................................................... 15 
Replacing filters elements ........................................................................................................ 16 
Setting outlet air pressure ........................................................................................................ 17 
Cleaning the pressure regulator............................................................................................... 17 
Replacing the inlet filter (21) .................................................................................................... 17 
Replacing the piston, connecting rod and piston rings ............................................................ 18 
Replacing the bearing: ............................................................................................................. 18 
Control electronics - 115V version ........................................................................................... 19 
Control electronics - 230V version ........................................................................................... 21 
Stabilizing the compressor before shipping ............................................................................. 25 
SHUT-DOWN ...................................................................................................................................... 25 
EQUIPMENT DISPOSAL .................................................................................................................... 25 
BATTERY DISPOSAL ......................................................................................................................... 25 
6.  TROUBLESHOOTING ................................................................................................ 26 
7.  SPARE PARTS ........................................................................................................... 27 
8.  ELECTRIC AND PNEUMATIC DIAGRAMS................................................................ 28 
WIRING DIAGRAM ............................................................................................................................. 28 
PNEUMATIC DIAGRAM ..................................................................................................................... 29 
9.  LIST OF SPARE PARTS ............................................................................................. 30

SM-DK50 DS-GB-11_08-2012
 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.

SM-DK50 DS-GB-11_08-2012 1
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.

2 SM-DK50 DS-GB-11_08-2012
 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 packaging – Fragile, handle with care

Handling mark on packaging – This way up (upright position)

Handling mark on packaging – Protect against moisture

Mark on packaging – Recyclable material

Handling mark on packaging – Temperature during storage and

transport

Handling mark on packaging – Limited stacking

Alternating current

Ground connection

Equipotentiality

Fuse

Condensate drain

Never dispose of the battery with common household waste.

SM-DK50 DS-GB-11_08-2012 3
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.)

4 SM-DK50 DS-GB-11_08-2012
 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).

SM-DK50 DS-GB-11_08-2012 5
EQUIPMENT DESCRIPTION

6 SM-DK50 DS-GB-11_08-2012
 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
230/60 / 2.8
230/60 / 2.8 230/60 / 3
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 900 mm ( 22 x 25 x 35.5 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 62 kg ( 137 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

SM-DK50 DS-GB-11_08-2012 7
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!

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.

8 SM-DK50 DS-GB-11_08-2012
 OPERATION

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
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.

SM-DK50 DS-GB-11_08-2012 9
OPERATION

 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)

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 maximum load on the upper trolley plate is 30 kg!

10 SM-DK50 DS-GB-11_08-2012
 OPERATION

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.

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

SM-DK50 DS-GB-11_08-2012 11
OPERATION

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.

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.

12 SM-DK50 DS-GB-11_08-2012
 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

SM-DK50 DS-GB-11_08-2012 13
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

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

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

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

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
Number 025200194 073000109 024000881 025900018 072000009
pc 1 1 2 1 2 1 1

14 SM-DK50 DS-GB-11_08-2012
 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

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

Safety valve check

The safety valve is adjusted to 8 bar by the manufacturer, then tested

and marked. It must not be readjusted!

 Turn the screw of the safety valve

(17) several rotations to left until the
safety valve puffs.
 Only allow the safety valve freely
puff for a short period of time.
 Turn the screw to the right until it is
tight, closing the valve.

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:

 Check the status of the compressor motor for balanced operation or noise.
 Check the condition of the hangers above the pump.

SM-DK50 DS-GB-11_08-2012 15
MAINTENANCE

 Check fan functionality.

 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.

Unscrew the filter holder.
Replace the filter and screw the filter holder into place.
Screw the cover back in place.

Spare filtration pads:

40 μm - white (19a) Item 025200204
5 μm- white-red (19b) Item 025200205

16 SM-DK50 DS-GB-11_08-2012
 MAINTENANCE

Setting outlet air pressure

To unlock the control button of the

regulator (20), raise it slightly and rotate
it to set the demand outlet pressure.
After setting the pressure, lock the
control button of the regulator by
pushing it down.

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

SM-DK50 DS-GB-11_08-2012 17
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.
 Fit a new connecting rod onto the bearing (ca. 1 - 1.5 mm from crank),
replace the cylinder (7) and secure it with the cylinder fitting (12) (Part No.
023000239) using 2 screws. After turning the crank a minimum of 10
times, check the position of the piston’s connecting rod (11) and tighten
the screw (8) on the connecting rod. 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

18 SM-DK50 DS-GB-11_08-2012
 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

SM-DK50 DS-GB-11_08-2012 19
MAINTENANCE

Procedure for entering operating hours into the new circuit board:

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

v.1.0.1 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.1.0.1” 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.

20 SM-DK50 DS-GB-11_08-2012
 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

SM-DK50 DS-GB-11_08-2012 21
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.

22 SM-DK50 DS-GB-11_08-2012
 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

SM-DK50 DS-GB-11_08-2012 23
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.

24 SM-DK50 DS-GB-11_08-2012
 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.

SM-DK50 DS-GB-11_08-2012 25
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

26 SM-DK50 DS-GB-11_08-2012
 SPARE PARTS

7. SPARE PARTS

 Air intake filter (15 ) 025000018

 Filtration inserts (19a) 025200204
 Filtration inserts (19b) 025200205
 Fuse
version 230V T6,3A 038100004
100V, 120V T10A 038100005
 Insertion DISS 1160-A 024000261
 Suction filter 05W POLYESTER 025200194

27 SM-DK50 DS-GB-11_08-2012
ELEKTRIC 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

28 SM-DK50 DS-GB-11_08-2012
 ELEKTRIC 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

SM-DK50 DS-GB-11_08-2012 29
 LIST OF SPARE PARTS

9. LIST OF SPARE PARTS

230V/50Hz 603011741 230V/50Hz 603011955
230V/60Hz 603011825 Air pump DK50 DS 230V/60Hz 603011918
Air pump DK50 DS
115V/60Hz 603011826 Model advanced 115V/60Hz 603011957
Model basic
100V/50-60Hz 603011827 100V/50-60Hz 603011958
120/60Hz UL 603012084
230V/50Hz 603011918
Air pump DK50 DS 230V/60Hz 603011741
Model standard 115V/60Hz 603011959
100V/50-60Hz 603011956

1 Screw M6x90 041000530 16 Crank

2 Washer 6 043000007 Model basic, standard
604031117
3 Cylinder head compl. 4DA-119 604031119 Model advanced 115/60,230/60
4 Spring II 4KA-019 022000010 Model advanced 100/50-60,230/50 604031405
5 O-ring 50x2 073000109 17 Screw M8x16 041000051
6 Valve plate 4CA-023 604021023 18 Crank case
7 Cylinder Model basic, standard
024000950
Model basic Model advanced 115/60,230/60
Model advanced 100/50-60,230/50 050000049 Model advanced 100/50-60,230/50 024001273
Model standard 115/60,230/60 19 Screw M6x25 041000501
Model advanced 115/60,230/60 20 Ledge 4KC-665 023000911
050000063
Model standard 100/50-60,230/50 21 Washer 6,4 043000010
8 Washer 22 Washer 6 043000007
Model basic 115/60, 230/60 23 Nut M6 042000005
024001190
Model advanced 230/50 24 motor
9 Piston with piston rod 1LF9073-4AJ99-ZN58 230V/50Hz 035110010
Model basic, standard 604021396 - Capacitor 16 MF 031330007
Model advanced 100/50-60,230/50 604021372 motor
10 Piston ring 069000123 1LF9073-4AJ99-ZN60 115V/60Hz 035110013
11 Screw IMB M6x25 041000115 - Capacitor 60MF/250V 031330034
12 Crank case cap 3KC-404 050000050 motor - UL
13 Screw M4x10 041000110 1LF9073-4AJ99-ZN26 120V/60Hz 035110034
14 Fiting G1/4 MF 024000948 - Capacitor MLR25, 60MF/250V 031330036
15 Bearing 6204 024000881 motor
1LF9073-4AJ99-ZN61 100V/50-60Hz 035110019
- Capacitor
25 Fiting G3/8 024000324
26 Fitting 025400034

SM-DK50 DS-GB-11_08-2012 30
 LIST OF SPARE PARTS

Compressor DK50 DS

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

28 Bottle LUH-1 062000333 Model basic 230V/50Hz 603011741
29 Check valve 3/8" MF 025300026 230V/60Hz 603011825
30 Foam 061000285 115V/60Hz 603011826
31 Fan 230V/50-60Hz 035300006 100V/50-60Hz 603011827
115V/60Hz 035300005 120/60Hz UL 603012084
32 Hanger 4BA-779 604011779 Model standard 230V/50Hz 603011918
33 Foam 061000284 230V/60Hz 603011741
34 Screwing 025500161 115V/60Hz 603011959
35 Frame 3DA-099 603031099 100V/50-60Hz 603011956
36 Hanger 4BA-947 604011947 Model advanced 230V/50Hz 603011955
37 Solenoid valve compl. 230V 603011740 230V/60Hz 603011918
115V,100 V 603011828 115V/60Hz 603011957
100V/50-60Hz 603011958
38 Angular screwing 025500238
39 Reduction 025400163
40 Fiting T 8-1/4 025400231
41 Fiting L G1/8 M/F 025400020
42 Hose D8x400 072000009 a Hose PA 8/6 blue 072000048
43 Safety valve 025300058 b Hose PA 6/4 neutral 072000026
Safety valve UL 025300069 c Hose PU 6x4x1 black 072000030
44 Insertion 025400175

SM-DK50 DS-GB-11_08-2012 31
LIST OF SPARE PARTS

Compressor DK50 DS

46 Shuttle valve 025300022 66 Fastener 029000122

47 Angular screwing L 8/6-1/4" 025500122 67 Angular screwing 025500193
48 Coupling G1/4 FF 024000947 68 Block of filters complete 3CA-272 604021641
49 Switch 033500025 69 Elektronic 230V 035900085
Switch UL 033500032 - control module, batery 230V 035900108
50 Connector 033200060 - keyboard 035900109
51 Quick-acting coupling with 4KB-494 024000492 Elektronic 115V,100V 035900060
valve 120V
52 Pin for mains connection 024000364 - control module, batery 035900107
- keyboard 035900055
53 Fuse holder 033200061 70 Block of filters 025900023
54 Quick-acting coupling without 4KB-493 024000493 - filter 40 µm
valve
55 Cooler complete 4CA-250 604021250 - regulator
56 Rubber leg 074000123 - filter 5 µm
57 Screw 041000702 71 Angular screwing 025400162
58 Fitting 6 025500236 72 Screwing 025500245
59 Coupling 6/4 025400154 73 Reduction 025400163
60 Angular screwing 025400153 74 Screwing 025500244
61 Coupling T 6x4 025400041 75 Filter silencers FS-05-025 025200115
62 Bumper 029000130 - Suction filter 025200194
63 Fastener 029000121
64 Weel 029000119
65 Weel braking 029000120

32 SM-DK50 DS-GB-11_08-2012
 LIST OF SPARE PARTS

Compressor DK50 DS

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

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

SM-DK50 DS-GB-11_08-2012 33