MEDICAL COMPRESSOR

DK50 DS

MANUFACTURER

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

www.ekom.sk
email: [email protected]
 CONTENTS

CONTENTS
1. GENERAL INFORMATION............................................................................................ 2
PURPOSE..............................................................................................................................................2
OPERATOR'S RESPONSIBILITY FOR PATIENT SAFETY .................................................................2
MARKING ..............................................................................................................................................2
WARNINGS ...........................................................................................................................................2
General safety warnings .............................................................................................................3
Electrical system safety warnings...............................................................................................3
ALERT NOTICES AND SYMBOLS .......................................................................................................4
USE ........................................................................................................................................................5
STORAGE AND TRANSPORT..............................................................................................................5
2. DEVICE DESCRIPTION................................................................................................. 6
3. TECHNICAL DATA........................................................................................................ 8
4. OPERATION .................................................................................................................. 9
INSTALLATION AND FIRST OPERATION ...........................................................................................9
Removal of transport stabilizers .................................................................................................9
Wheels installation......................................................................................................................9
Compressed air connection ......................................................................................................10
Electrical connection.................................................................................................................10
First operation ...........................................................................................................................10
Accessories...............................................................................................................................11
PERSONNEL .......................................................................................................................................12
Switching the compressor on....................................................................................................12
Running the compressor...........................................................................................................12
Cleaning and replacing the filters .............................................................................................13
Cleaning the compressor..........................................................................................................13
5. MAINTENANCE ........................................................................................................... 14
REPAIRS AND SERVICE ....................................................................................................................14
MAINTENANCE SCHEDULE ............................................................................................................14
Service kit .................................................................................................................................14
Maintenance replacement parts ...............................................................................................15
Maintenance replacement parts ...............................................................................................15
Safety valve check....................................................................................................................15
Check tightness of joints and inspect the appliance.................................................................15
Replacing filters in filter (19) .....................................................................................................16
Setting output air pressure........................................................................................................16
Replacing the suction filter (21) ................................................................................................17
Replacing the piston, connecting rod and piston rings.............................................................17
Replacing the bearing:..............................................................................................................18
Replacement of Printed Circuit (PS) SMART: ..........................................................................18
Stabilizing the compressor before shipping..............................................................................24
SHUT-DOWN.......................................................................................................................................24
DISPOSAL OF THE APPLIANCE........................................................................................................24
ACCUMULATOR DISPOSAL ..............................................................................................................25
6. TROUBLESHOOTING ................................................................................................. 25
7. PARTS LIST ................................................................................................................ 26
BASIC COMPONENTS........................................................................................................................26
ACCESSORIES ...................................................................................................................................26
8. ELECTRIC AND PNEUMATIC DIAGRAMS ................................................................ 27
WIRING DIAGRAM ..............................................................................................................................27
PNEUMATIC DIAGRAM ......................................................................................................................28
9. LIST OF SPARE PARTS ............................................................................................. 29

SM-DK50 DS-GB-3 1
GENERAL INFORMATION

1. GENERAL INFORMATION

PURPOSE

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

OPERATOR'S RESPONSIBILITY FOR PATIENT SAFETY

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

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

Rx only

MARKING

Products marked with the CE mark of compliance meet the safety guidelines
of the European Union (93/42/EEC).

WARNINGS

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

appliance 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 device.
• The warranty does not cover damages resulting from the use of
accessories or consumable material other than those recommended by
the manufacturer.
• The manufacturer assumes responsibility for the safety, reliability and
function of the appliance only if:
- installation, calibration, amendments, extensions and repairs are
performed by the manufacturer or its representative, or a service provider
authorized by the manufacturer
- the appliance 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 schemes,
methods and names.

2 SM-DK50 DS-GB-3
 GENERAL INFORMATION

General safety warnings

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

note the following safety measures to avoid injury or damage.

• Operation of the device must be in compliance with all local codes and
regulations.
• The original packaging should be kept for the possible return of the unit.
Only original packaging ensures optimal protection of the appliance during
transport. If it is necessary to return the appliance during the warranty
period, the manufacturer is not liable for damages caused by incorrect
packaging.
• If any problem occurs during use of the appliance, the user must notify his
supplier immediately.
• This product is not intended for use in areas with risk of explosion. Do not
operate the compressor in the presence of flammable anesthetics.
• Never put oxygen or nitrous oxide into the compressor. The components
are not approved for oxygen or nitrous oxide use.

Electrical system safety warnings

• The appliance must be connected to earth (grounded). To assure correct

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

SM-DK50 DS-GB-3 3
GENERAL INFORMATION

ALERT NOTICES AND SYMBOLS

In the Installation, Operation and Maintenance Manual and on packaging and

product, the following symbols are used for important information:

Information or instructions to prevent injury or material damage

Caution! Dangerous electrical voltage

Special information regarding the correct use of the appliance and

other warnings

CE mark of compliance

Caution! Hot surface

Handling mark on packaging – Fragile, handle with care

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

freight)

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

Earth (ground) connection

Connector for earth ground pin

Fuse

Condensate outlet

Never dispose of the accumulator with common household waste.

4 SM-DK50 DS-GB-3
 GENERAL INFORMATION

USE

• The appliance 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, sufficiently stable base.
• The compressor must not be exposed to rain. The appliance must not be
used in humid or wet environments. Never use the compressor in the
presence of flammable liquids or gasses.
• Before connecting the compressor to a respiratory appliance, make sure
that it meets the requirements of the respiratory appliance. 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. This risk is assumed only
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 can 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 before shipping.

SM-DK50 DS-GB-3 5
DEVICE DESCRIPTION

2. DEVICE DESCRIPTION

1. Display – the primary display indicates output pressure

2. PRESSURE - alarm at low output pressure
3. TEMP - alarm at high operating temperature
4. DRYING – indicates drying level; yellow = unsatisfactory, green =
satisfactory
5. MAINS - alarm at loss of power
6. TIME – when the button is pressed, the number of operation hours is
displayed
7. BATTERY – indication of weak battery = yellow
8. POWER – indication of device turned on = green
9. OUT - output air from compressor
10. WALL - input air coming from an outside compressed air source
11. Main input, power switch, primary fuses
12. Equipotential (ground) pin
13. Socket for the electrical cord
14. Condensate vessel
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. Suction 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 a cooler (23) where condensed water is
separated into a vessel (14). Incoming air passes through two filters (15, 21) and
undergoes 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 pressure at output 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 source of air. In this configuration, the respiratory
equipment is supplied with compressed air from the central air distribution of the medical
facility. Air pressure in the central distribution is sensed 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 need for air. If air consumption is zero, the device
switches to STANDBY mode.
The compressor is equipped with indicators for output pressure (1), operation hours (6),
power status (8), drying sufficiency (4) and battery condition (7). The acoustic and optic
alarms activate to warn of high operating temperature (3), low output pressure (2) and loss
of power (5).

6 SM-DK50 DS-GB-3
 DEVICE DESCRIPTION

SM-DK50 DS-GB-3 7
TECHNICAL DATA

3. TECHNICAL DATA

TYPE DK50 DS
-1
40 L.min
Output flow -1
50 L.min
200* L.min ( 7 Cft. min-1 )
-1
Peak flow
USA Model
Voltage / Frequency V/Hz 230/50 230/60 120/60 100/50-60
Nominal current A 2.8 2.8 5.6 5.6
Air filtration µm 5
-1 5°C (9°F) below the ambient temperature
Pressure dew point at 40 L.min
10°C (18°F) below ambient temperature – version with membrane
( 1.4 Cft. min-1 ), 3 bar( 43.5 psig ), 20°C (68°F)
dryer
DISS 1160-A (3/4"-16 UNF)
Outlet connection
NIST (EN 739)
Sound level dB(A) ≤ 50 ≤ 51 ≤ 51 ≤ 51
Mode of operation Continuous - S1
Separation of condensed water Automatic
Yellow (working pressure < 2,4 bar (34.8 psig) )
Indication of drying
Green (working pressure ≥ 2,4 bar (34.8 psig) )
Alarm of low pressure Decrease in output pressure under 2.1 bar ( 30.5 psig )
Alarm of cooling failure Increase in internal temperature above 80°C (176°F)
Output pressure Adjustable to max. 3.5 bar (51 psig)
Decrease in pressure in the central distribution under
Automatic turn-on pressure
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 8 bar ( 116 psig )
Adjustment of output 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 30 kg ( 66 lbs )
Net weight of compressor with weels 31 kg ( 68 lbs )
Net weight of compressor with trolley 47 kg ( 104 lbs )
Gross weight 37 kg ( 82 lbs )
Gross weight of compressor with weels 38 kg ( 84 lbs )
Gross weight of compressor with trolley 54 kg ( 119 lbs )
Implementation according to EN 60601-1, EN 12021 Type B class I.
Classification according to MDD 93/42 EEC II b
* With 0.6 bar 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 +5°C to +40°C (+41°F to +104°F)
Relative air humidity up to +95%
IPX0 Rating

8 SM-DK50 DS-GB-3
 OPERATION

4. OPERATION

INSTALLATION AND FIRST OPERATION

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

adjust for 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 appliance.
Installation and training of personnel should be acknowledged by the
installer‘s signature on the certificate of installation.

Prior to start-up, 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 in backside and the ventilating outlets
on the upside of the appliance.

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.

Wheels installation

For versions of a compressor with wheels must be installed wheels

according to figure.

SM-DK50 DS-GB-3 9
OPERATION

Compressed air connection

The medical compressor is equipped with fast-on couplings WALL (10) and
OUT (9) on the rear of the cabinet.

To the fast-on coupling OUT (9) -output compressed air- connect the
pressure hose leading to the applicable appliance/respiratory apparatus.

To the fast-on coupling WALL (10) -input compressed air- connect

pressurized air from a central distribution system, if applicable. The air from
the distribution system is automatically connected through the compressor to
the outlet OUT 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 of continuously pressurized air at the output from the
compressor.

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

The hose connecting the compressor to the breathing apparatus must

not pass through a cold environment i.e. placed on the ground. It
should be as short as possible with no kinks.

Electrical connection

The compressor comes with a plug containing an appropriate

protective contact (ground.) Adhere to local electrical regulations. The
mains voltage and frequency 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 appliance
can be safely disconnected from the mains supply in case of emergency.
• The relevant current circuit must be safeguarded.
• Connection of the ground connection (12) to other appliances must adhere
to local electrical regulations.
• Fasten down 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 mains supply.

10 SM-DK50 DS-GB-3
 OPERATION

• 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,

the mains 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 and, if that pressure falls, the
compressor switches on.
• When pressure is low in the central air distribution, or if the device is not
connected to the central distribution, the compressor permanently works. If
there is no air consumption at the output, the device switches to STANDBY
mode. When air consumption resumes, the compressor automatically
switches on.
During operation, the device drains off the entrapped condensed water from
pneumatic circuits via automatic filter separators into a vessel.

Accessories

Rack SD 30 (24)

The rack accommodates the compressor, a ventilator 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 platte axis (1):
Trolley without compressor - 25kg
Trolley with compressor - 30kg

Maximum loading of upper plate of rack is 30 kg!

Humidifier holder (25)

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

SM-DK50 DS-GB-3 11
OPERATION

PERSONNEL

In case of emergency, switch the appliance off at the switch and pull
out the mains plug.

Switching the compressor on

The compressor is switched on at the mains 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. Display displays
the value of output pressure with accuracy ± 5% in BAR or PSI units. An
indicator is lit on the display next to the relevant unit. Ask serviceman for a
change of display of units if necessary. After pressing the TIME (6) button,
the display shows the number of hours in operation. Indicator DRYING (4)
displays the drying status. Green indicates satisfactory drying; yellow
indicates unsatisfactory drying. If the yellow indicator DRYING (4) stays on,
make sure that the air consumption from the compressor did not exceed the
output flow according to specification. If air consumption is within normal
parameters, contact servicing centre.

The decrease in output pressure is indicated by alarm PRESSURE (2) which

sounds an alarm and illuminates the yellow indicator. The alarm is activated
if the output pressure does not reach the required level and also 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 did not
exceed the output flow according to specification. If air consumption is within
normal parameters, contact servicing centre.

Cooling failure is indicated by 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 venting holes were covered, the filter in the
bottom part of the compressor is contaminated or the compressor works in
environment with higher temperature. If none of these circumstances apply,
a malfunction has occurred and service is required.

Alarm MAINS (5) is activated upon the interruption in the powering of

compressor.

Illumination of yellow indicator BATTERY (7) signals low battery. During the
equipment operation the battery is recharged automatically. 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. Exchange the battery for identical type
with the original one - NiMH 9V 200mAh.

12 SM-DK50 DS-GB-3
 OPERATION

Used accumulators may not be processed as household waste, they must be

collected separately.

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

Cleaning and replacing the filters

At least once a week take out and clean the output filter (15) located on the
back side. Wash the filter in warm soapy water, rinse thoroughly and allow
them 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.

SM-DK50 DS-GB-3 13
MAINTENANCE

5. MAINTENANCE

REPAIRS AND SERVICE

Guarantee and extended guarantee repairs are to be completed by the

manufacturer or a service provider authorized by the manufacturer.

The manufacturer reserves the right to modify the appliance in any way
that will not alter the function or the operation of the appliance.

Only a qualified technician or the Customer Service Deptartment 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 mains plug).

MAINTENANCE SCHEDULE

Time interval (Hour)

Maintenance Page
4000 8000
Safety valve check 15 1 x per year
Test the tightness of joints and
15 - 16 after two years
inspect the appliance
Replace service kit A (filters) 14 x x
Replace service kit B 14 x

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 230V Part No. 604041078

typ DK50 DS 100-120V Part No. 604041079

B
Piston with Filter coverSolenoid
8000 hrs . Suction filter O-ring Bearing Hose
rod complete
bubble to according to
Type 4KA-292 4CA-396 D50x2 6204 2RS DN8x400
AF20,AW20 model
Number 025200139 604021396 073000109 024000881 025900018 072000039
pc 1 1 2 1 2 1 1

14 SM-DK50 DS-GB-3
 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.
• Let the safety valve freely puff only
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 depressurize the air tank. This could damage
the safety valve.

Check tightness of joints and inspect the appliance

Test for leakage:

• Disconnect the output hose from fast-on coupling OUT (9); the
consumption of compressed air is stopped.
• 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, then test the ones inside the case after
removing the covers.
• Tighten or re-seal joints as necessary.

Inspect the appliance:

• Check the status of the compressor aggregate- balanced operation,
noisiness.
• Check the condition of the hangers above the pump.
• Checking the fan functioning.

SM-DK50 DS-GB-3 15
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:
- impurities in the crankcase
- free movement of the crank shaft
• If necessary, replace any faulty parts.

Replacing filters in filter (19)

Before beginning, reduce air pressure in the tank to zero and
disconnect the appliance from the 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. 26
• Screw the cover back in place.

Spare filtration pads:

Bronze (40 µm) (19a) AF20P-060S-7-40B art. 025200142
Plastic (5 µm) (19b) AF20P-060S art. 025200113
If the water release system becomes clogged, disassemble release valve (f),
clean the outlet, remove float (b) with lever mechanism (c, d, e) from the
vessel, clean them all with a soap solution and reassemble.

Setting output air pressure

To unlock the control button of the

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

16 SM-DK50 DS-GB-3
 MAINTENANCE

Replacing the suction filter (21)

• Unlock the cover and pull it out.

• Replace the filter
• Lock the cover
Spare part:
Intake filter 05 POLYESTER, Art. 025200139

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.

SM-DK50 DS-GB-3 17
MAINTENANCE

Replacing the bearing:

Disassembly

• 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.

Replacement of Printed Circuit (PS) SMART:

• Safely disconnect the device from powering mains,

• Disassemble rear panel of compressor,
• Disconnect hoses, connector and wires on PS,
• Disassemble PS and replace it with a new one,

18 SM-DK50 DS-GB-3
 MAINTENANCE

• Connect wires and connector according to wiring diagram,

• Prior to putting the compressor into operation, it is necessary to check for
the correctness of the operation of PS using “SERV_SMART v.1.0.1”
software, “RS232 SERVIS SMART” cable and device for pressure
measurement. In the case there is any error, it is necessary to proceed
according to the bellow given procedure, and
• After verifying the operation of PS connect hoses according to Fig.,
assemble rear panel, connect vessel for condensate trapping.

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.

SMART electronics is produced in two versions 230V and 110V. Only

powering transformer is different on the boards. For the given reasons,
just 230V version is described hereinafter. However, all hereinafter
stated information are valid also for 110V version.

Checking for the Correctness of Sensor Calibration:

• Check for the faultlessness of the connection of power leads on module

terminal board. (Mains 230V AC or 110V AC, engine, electromagnetic
valve, ventilators)
• Check for the faultlessness of the connection of electronics control panel
with keypad.
• In the case power leads are flawlessly connected, assess the incorrect
operation of the compressor as follows:

- For further diagnostic process use PC with “SERV_SMART v.1.0.1”

software. Connect the computer just with the compressor using “RS232
SERVIS SMART“ cable for PC. The correctness of cable connection and
selection of a correct communication port on PC is indicated by displaying
measured values of pressures, temperature and worked out hours. The
number of worked out hours is read just once at the software start-up, the
values of pressures and temperature are displayed in a real time. Time data
on worked out hours is up-dated every fifteen minutes, however software

SM-DK50 DS-GB-3 19
MAINTENANCE

shall not display this up-date. The reason of this solution is not to interrupt
processor and let it regulate.
- Check whether the compressor works correctly in the corresponding working
mode and whether SoftStartStop functions works correctly on the basis of
the values of working and output pressure.
- In the case the incorrect function is indicated in clause 2 due to incorrect
calibration, remedy the fault using PC with “SERV_SMART v.1.0.1” software
by zeroing the offset of pressure sensors. When zeroing the offset of
pressure sensor, consistently take care after ensuring zero pressure in the
system. Offset zeroing without calibration is a makeshift solution.
- The compressor is constantly on or constantly off. Attempt to remedy the
fault using PC with "SERV_SMART v.1.0.1” software by setting the standard
initial condition followed by calibration. In the case the electronics does not
communicate, i.e. no values from the measurement of pressures,
temperature and worked out hours are displayed in the entrance window and
we are sure the communication cable is correctly connected and
communication port on PC is correctly set, the electronics board must be
replaced.
- In the case the compressor works correctly, “SERV_SMART v.1.0.1”
software displays the correct values of pressures and temperature and
incorrect data are on the foil keypad, the replacement of keypad board with
connecting cable is necessary.

Fig. 1

Standard Initial Condition Setting

For setting the standard initial condition use PC with “SERV_SMART v.1.0.1”
software. Connect the computer with the compressor using “RS232 SERVIS
SMART” cable for PC. The correctness of cable connection and selection
of the correct communication port on PC is indicated by displaying the
measured values of pressures, temperature and worked out hours. The
displayed values are changing with the changes of the values of pressures

20 SM-DK50 DS-GB-3
 MAINTENANCE

and temperature. Set the initial standard condition by clicking SETUP button.
This command writes the initial regulation parameters into EEPROM
memory of control microprocessor. Manufacturer recommends the
increased caution when using this command since this command
overwrites calibration! For this reason operator must respond to a question
„Are You Sure?". The acknowledgement of record is indicated by “„Default
Calibration and Setup OK“ message sent back by the microprocessor. After
setting the standard initial condition, the compressor shall work flawlessly but
the values of pressures and temperatures shall not be accurately set. The
increase of accuracy of pressure measurement shall be achieved by
measuring pressure sensor offset zeroing. Carry out the accurate setting of
these values in calibration mode.

Pressure Sensor Offset Zeroing

Use PC with “SERV_SMART v.1.0.1” software for sensor offset zeroing.

Turn on DK50 DS compressor with zero output consumption of compressed
air set. When SMART board starts communicating with PC, CAL message is
displayed on the display of SMART electronics.
Connect the computer with the compressor using “S232 SERVIS SMART”
cable. When electronics gets “STANDBY” mode, working pressure reaches
almost the maximal value, start “SERV_SMART v.1.0.1” software.
• Click “NUL” button.
• A call for ensuring zero pressure within the system shall appear on the
computer. After ensuring zero pressure, confirm OK.
• The acknowledgement of zeroing the relevant sensor is indicated by
“Calibration OK” message sent back by the microprocessor.

Execute the described operation for both sensors.

Calibration

Use PC with “SERV_SMART v.1.0.1“ software for calibration. Connect the

computer with the compressor using “RS232 SERVIS SMART” cable. The
correctness of the cable connection and setting the correct communication
port on PC is indicated by displaying the measured values of pressures,
temperature and worked out hours on PC. Use device made pursuant to
Fig.2 for the connection and measurement of pressure from compressor.

Compressor

Fig. 2

SM-DK50 DS-GB-3 21
MAINTENANCE

Calibration of Working Pressure P1

• Connect the measuring device - Fig. 2 onto the outlet of air from
compressor.
• Set regulation valve of output pressure of compressor so that the value of
its output pressure was the same as the value of working pressure.
• Turn on DK50 DS compressor with zero output consumption of
compressed air set. When electronics gets “STANDBY” mode, working
pressure reaches almost the maximal value, start “SERV_SMART v.1.0.1”
software. Activate “CAL” button from "Working Pressure” environment.
When SMART board starts communicating with PC, the compressor shall
stop and CAL message is displayed on the display of SMART electronics
and OK status appears on the computer.
• Carry out calibration in two points withal the first point is the current value
of working pressure measured by calibration gauge. The second point is
the zero value of pressure we reach after the complete release of
compressed air from the compressor.
• The acknowledgement of calibration of the relevant sensor is indicated by
“Calibration OK“ message on PC“.

Calibration of Output Pressure P2

• Connect the measuring device – Fig. 2 onto the outlet of air from
compressor.
• Set regulation valve of output pressure of compressor so that the value of
its output pressure was the same as the value of working pressure.
• Turn on DK50 DS compressor with zero output consumption of
compressed air set. When electronics gets “STANDBY” mode, working
pressure reaches almost the maximal value, start “SERV_SMART v.1.0.1”
software. Activate “CAL” button from "Working Pressure” environment.
When SMART board starts communicating with PC, the compressor shall
stop and CAL message is displayed on the display of SMART electronics
and OK status appears on the computer.
• Carry out calibration in two points withal the first point is the current value
of working pressure measured by calibration gauge. The second point is
the zero value of pressure we reach after the complete release of
compressed air from the compressor.
• The acknowledgement of calibration of the relevant sensor is indicated by
“Calibration OK“ message on PC.

Calibration of Temperature t

• Execute the temperature calibration similarly as the calibration of working

pressure P1

22 SM-DK50 DS-GB-3
 MAINTENANCE

• Click CAL button from “Temperature” environment. When the SMART

board starts communicating with PC, CAL message appears on the
display of SMART electronics and OK status appears on the computer.
• Carry out calibration or “upwards” in two points withal the first point is the
current temperature of working environment in which thermal sensor is
located for a long time. Temperature of working environment is measured
using calibration gauge. The second point is the current temperature of
water – homogeneous environment (80°C±10°C), in which thermal sensor
is immersed. Temperature of water is measured using calibration gauge.
• The recommended values of temperature at calibration are 25°C±5°C and
80°C±10°C
• The acknowledgement of calibration of thermal sensor is indicated by
"Calibration OK" message on PC.

CAUTION! When calibrating, concentrate mainly on the accurate setting

of the upper calibration point since the electronics generates second
class alarm signal at temperature of 80°C.

Fig. 3
P1 P2 t

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

SM-DK50 DS-GB-3 23
MAINTENANCE

1 2 3

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
four original screws M6 (see picture)
and plastic cover assemble.

SHUT-DOWN

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

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

DISPOSAL OF THE APPLIANCE

• Disconnect the appliance from the mains supply.

• Release the pressure in the air tank.
• Dispose of the appliance according to local regulations.
• The parts used in this product have no negative impact on the
environment when disposed of properly.

24 SM-DK50 DS-GB-3
 TROUBLESHOOTING

ACCUMULATOR DISPOSAL

Accumulator may not be disposed with common household waste. Disposal

non-functional accumulator in collecting place.

6. TROUBLESHOOTING

Prior to servicing the appliance, reduce the pressure in the air tank to
zero and disconnect the appliance from the mains supply.

Only trained service personnel can perform the activities listed in the
troubleshooting guide.
PROBLEM POTENTIAL CAUSE SOLVING COMMON PROBLEMS
The STANDBY mode, the compressor starts
There is pressure in the air tank
upon the pressure decrease
Switched off mains breaker in distribution
system
Check supply
No mains voltage
Compressor does Replace the defective fuse
not start Loose wire terminal – tighten
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 filter Clean or replace the dirty air blow 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

SM-DK50 DS-GB-3 25
PARTS LIST

7. PARTS LIST

BASIC COMPONENTS

• Compressor 1 pc
• Installation, Operation and Maintenance Manual 1 pc
• Air intake filter (15) 025000018 1 pc
• Filtration inserts (19a)(Bronze)AF20P-060S-7-40B 025200142 1 pc
• Filtration inserts (19b)(Plastic) AF20P-060S 025200113 1 pc
• Fuse 2 pcs
Version 230V T6,3A 038100004
100V, 120V T10A 038100005
• Insertion DISS 1160-A 024000261 2 pcs
• Screw-wrench No. 3 192000005 1 pc
• Wrench for de-fixation and replacement of filtration inserts
023000933 1 pc

ACCESSORIES

These items are not components of the compressor and must be ordered
separately.

• Rack (24) 602021222 1 pc

• Humidifier holder (25) 604031175 1 pc

26 SM-DK50 DS-GB-3
 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

SM-DK50 DS-GB-3 27
ELECTRIC AND PNEUMATIC DIAGRAMS

PNEUMATIC DIAGRAM

10 11
4 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

28 SM-DK50 DS-GB-3
 LIST OF SPARE PARTS

9. LIST OF SPARE PARTS

Air pump DK50 DS 230V/50Hz 603011741
230V/60Hz 603011825
115V/60Hz 603011826
110V/50-60Hz 603011827

1 Screw M6x90 041000530 16 Crank 4CA-289 604021289

2 Washer 6 043000007 17 Screw M8x16 041000051
3 Cylinder head compl. 4DA-119 604031119 18 Crank case 4KC-402 024000950
4 Spring II 4KA-019 022000010 19 Screw M6x25 041000501
5 O-ring 50x2 073000109 20 Ledge 4KC-665 023000911
6 Valve plate 4CA-023 604021023 21 Washer 6,4 043000010
7 Cylinder 3KC-403 050000049 22 Washer 6 043000007
8 Washer 4KC-977 024001190 23 Nut M6 042000005
9 Piston with piston rod 4CA-396 604021396 24 Motor 230V/50Hz 035110010
10 Piston ring 069000123 1LF9073-4AJ99-ZN58
11 Screw M4x12 041000095 - Capacitor 16 MF 031330007
12 Crank case cap 3KC-404 050000050 24 Motor 115V/60Hz 035110013
13 Screwing L 8/6-1/4 025500122 1LF9073-4AJ99-ZN60
14 Fitting G1/4 MF 024000948 - Capacitor 60MF/250V 031330034
15 Bearing 6204 024000881 25 Screw IMB M6x25 041000115

SM-DK50 DS-GB-3 29
LIST OF SPARE PARTS

Compressor DK50 DS 230/50 430402000

115/60 430402200
26 Bottle cap 4KB-956 062000350 33 Frame 3DA-099 603031099
27 Bottle LUH-1 062000333 34 Safety valve 4BA-025 604011025
28 Fan 230V/50-60Hz 035300006 35 Gasket Cu 4KA-078 025900003
115V/60Hz 035300005 36 Air pump compl. 230V/50Hz 603011741
29 Hanger 4BA-779 604011779 230V/60Hz 603011825
30 Solenoid valve 230V 036100022 115V/60Hz 603011826
115V,100 V 036100045 110V/50-60Hz 603011827
31 Hanger 4BA-294 604011294 37 Fiting MF 3/8 025400034
32 Hose D8x400 072000009 38 Check valve 4KA-735 024000359

30 SM-DK50 DS-GB-3
 LIST OF SPARE PARTS

Compressor DK50 DS 230/50 430402000

115/60 430402200
39 Elektronic 230V 035900054 46 Screwing L 8/6-1/4" 025500122
115V,100V 035900060 47 Coupling G1/4 FF 024000947
40 Suction filter FS-05-025 025200115 48 Cooler complete 4CA-250 604021250
41 Connector 033200060 49 Fitting L 6 025400153
42 Switch 033500025 50 Screwing L 6/4 025400154
43 Fuse holder 033200061 51 Fitting T 6x4 025400041
44 Quick-acting coupling without valve 4KB-493 024000493 52 Block of filters 3CA-272 603021272
45 Quick-acting coupling with valve 4KB-494 024000492

SM-DK50 DS-GB-3 31
LIST OF SPARE PARTS

Compressor DK50 DS 230/50 430402000

115/60 430402200
53 Foam 4 4KC-505 061000287 59 Cover back 3DA-098 603031098
54 Foam 3 4KC-504 061000286 60 Cover with stiffeners 3CA-302 603021302
55 Foam 9 4KC-681 061000305 61 Keyboard K1/A 035900055
56 Foam 8 4KC-680 061000302 62 Keyboard cover 3KC-688 062000534
57 Filter 4KC-500 025000018
58 Foam 6 4KC-678 061000301

32 SM-DK50 DS-GB-3