INDUSTRIAL

AIR
COMPRESSOR
EKO D SERIES
(EKO 15-250 D)

EKO GD SERIES
(EKO 55-250 GD)

DIRECT DRIVE
&
GEAR DRIVE

PLEASE READ THIS MANUAL CAREFULLY BEFORE

START-UP THE COMPRESSOR

EKO 15 – 250 D
EKO 15 – 250 DVST
EKO 55 – 250 GD
EKO 55 – 250 GDVST

OPERATOR’S MANUAL
EKO-D-GD-UM-2009-2

Part No: 904402

 ROTARY SCREW
AIR COMPRESSOR

EKO D, EKO GD SERIES

MODEL : ...................................

SERIAL NO : ......................................

MAX . WORKING PRESSURE : ......................................

MIN. WORKING PRESSURE : ......................................

OIL TYPE : ......................................

OIL QUANTITY : ......................................

MOTOR POWER : ........... HP ........... kW

USER : .......................................

SOLD BY : .......................................

START-UP BY : .......................................

START UP DATE : .......................................

 INTRODUCTION

DEAR EKOMAK COMPRESSOR USER

Your compressor has been produced with advanced technology and the latest engineering standards, with the experiments of years. It is mostly
problem-free, efficiency and reliable if operated properly. Security must be main consideration on use as production.

EKO D and EKO GD air screw compressors has been made to produce the compressed air which is used for air tools, machines and process.

Manufacturer will not be liable for applications outside the scope of the machine intended use and this will void the warranty. However, any
machine might be a potential source of danger if improperly handled or use by unqualified, untrained or careless personel or if used the scope of
its intended use. Therefore, be sure to observe all instructions given in this manual and strictly comply with all local safety and accident
prevention rules and regulations.

DO NOTattempt to make any handling, locating, mounting, maintaining and repairing process unless read and understand this manual carefully.

Your compressor may deviate a few details from the illustrations shown in this manual. This is no importance for the operation of the machine.

Should any questions arise in spite of the instructions in this manual or if you have any inquiries concerning this manual or wish to obtain
additional copies, please do not hesitate to contact our Technical Service Department so they will glad to help you. Make sure the manual is kept
near the compressor and thus always at hand for the operaating personel.

This compressor should be operated and used only by trained and qualified person. No person is allowed to operate the compressor-even for only
a short time-without adequate-training.

The owner should clearly establish who is responsible for assembling, disassembling and reassembling the compressor for putting it into
operation, set up, operating and servicing the compressor.

The owner is obligated to operate the compressor only if it is in a safe condition. Major repairs must only be carried out by the manufacturer or
by specially authorized, qualified personel.

The operator is obligated to immediately remedy (if authorized) or report any defects or alterations that may affect the safety of the compressor.

Product safety signs or decals should be periodically inspected and cleaned or replaced when they no longer meet the legibility requirements for
safe viewing at a reasonable distance.

Make sure that enclosures removed for maintenance or repairs are refitted before restarting the compressor.

DO NOT remove, alter or deactive any machine parts such as safety valve, coupling guard, fan guard, combistat, extreme temperature switch,
temperature switch, fuses.

DO NOT begin any meintenance or adjustment work before the compressor has been switched off, P1 and P2 are –0- and make sure to secure
the compressor against accidental restart.

DO NOT use any flammable or explosive material for cleaning purposes.

DO NOT allow to be any flammable gases which may cause explosion or burning in the inlet air.

Keep the working area clean and tidy.

Only qualified electricians are allowed to do any work on the electric system.

Only use original EKOMAK spare parts for your compressor. We assume you to keep needed spares in your stock. DO NOT allow any
unauthorized companies or non-EKOMAK companies for part changes.

It is valid most restricted one of the rules about the security if any instruction in this manual is not comply with the local rules. Take additional
cares if necessary and take care of each handling, operating, maintanence and repairs even though it is not explained in this manual.

Compressors must be grounded.

DO NOT attempt to operate the compressor out of stated operating pressures. (operating pressure is indicated on the serial number plate)

READ THE MANUAL

Each authorized machine operator must have fully read the manual before working with the compressor. The person responsible for plant safety
should request all operators to confirm this by their signature.

I HAVE READ AND UNDERSTOOD THIS OPERATOR’S MANUAL

Signature Date

Owner ...................................... .............................................

Operators ...................................... ............................................

 TABLE OF CONTENTS

SECTION 1 SAFETY
1.1 GENERAL.................................................................................................................................................................... 1
1.2 PERSONAL PROTECTIVE EQUIPMENT................................................................................................................ 1
1.3 PRESSURE RELEASE................................................................................................................................................ 1
1.4 FIRE AND EXPLOSION............................................................................................................................................. 1
1.5 MOVING PART........................................................................................................................................................... 1
1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNER.................................................................................... 2
1.7 TOXIC AND IRRITATING SUBSTANCE................................................................................................................. 2
1.8 ELECTRICAL SHOCK................................................................................................................................................ 2
1.9 LIFTING AND HANDLING........................................................................................................................................ 2
1.10 ENTRAPMENT............................................................................................................................................................ 2

SECTION 2 INSTALLATION
2.1 LOCATION OF COMPRESSOR................................................................................................................................. 3
2.2 VENTILATION AND COOLING............................................................................................................................... 3
2.3 SERVICE AIR PIPING................................................................................................................................................. 3
2.4 OIL LEVEL CHECK.................................................................................................................................................... 3
2.5 ELECTRICAL PREPARATION.................................................................................................................................. 3
2.6 MOTOR ROTATION DIRECTION CHECK.............................................................................................................. 3

SECTION 3 SPECIFICATIONS
3.1 TECHNICAL SPECIFICATIONS............................................................................................................................... 4
3.2 LUBRICATION GUIDE.............................................................................................................................................. 4

SECTION 4 COMPRESSOR SYSTEMS

4.1 INTRODUCTION......................................................................................................................................................... 5
4.2 DESCRIPTION OF COMPONENT............................................................................................................................. 5
4.3 COMPRESSOR UNIT,FUNCTIONAL DESCRIPTION............................................................................................ 5
4.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION............................ 5
4.5 COMPRESSOR DISHARGE SYSTEM, FUNCTIONAL DESCRIPTION................................................................ 5
4.6 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION............................................................................................. 6
4.7 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION............................................................................................ 7
4.8 INSTRUMENT PANEL GROUP, FUNCTIONAL DESCRIPTION.......................................................................... 7
4.9 PURPOSE OF CONTROLS …………………………………………......................................................................... 8

SECTION 5 OPERATION
5.1 GENERAL.................................................................................................................................................................... 9
5.2 INITIAL START-UP PROCEDURE........................................................................................................................... 9
5.3 SUBSEQUENT START-UP PROCEDURE................................................................................................................ 9
5.4 SHUTDOWN PROCEDURE....................................................................................................................................... 9

SECTION 6 MAINTENANCE
6.1 GENERAL.................................................................................................................................................................... 10
6.2 DAILY OPERATION................................................................................................................................................... 10
6.3 PERIODIC MAINTENANCE …………………………………………..................................................................... 10
6.4 OIL MAINTENANCE.................................................................................................................................................. 10
6.5 OIL FILTER MAINTENANCE.................................................................................................................................... 11
6.6 SEPARATOR MAINTENANCE................................................................................................................................. 11
6.7 PARTS REPLACEMENT AND ADJUSTMENT PROCEDURES............................................................................. 11
6.8.A SERVICE INSTRUCTIONS FOR THREE-PHASE MOTORS ................................................................................. 14
6.8.B PIPING AND INSTRUMENTATION DIAGRAM .................................................................................................... 15
6.9 INVERTER MAINTENANCE AND INSPECTION FOR ALL VST COMPRESSORS .......................................... 16
6.10 MAINTENANCE RECORD ........................................................................................................................................ 17

SECTION 7 TROUBLESHOOTING
7.1 INTRODUCTION......................................................................................................................................................... 18
7.2 TROUBLESHOOTING................................................................................................................................................ 18

COOLING AIR EXHAUST DUCTS ………………………………………………………………………………… 21

CABLE SIZES ……………………………………………………………………………………………………….. 22
MOTOR BEARINGS LUBRICATION SCHEDULE……………………………………………………………….. 23
RECOMMENDED SPARE PARTS AND SERVICE OPERATIONS…………………………………………..….. 24

ANNEX PROCEDURE FOR ORDERING PARTS................................................................................................................... 25

SECTION 8 ILLUSTRATIONS AND PART LIST ……………………………….…… (see/read Part List book)
 1.SAFETY
1.1 GENERAL
EKOMAK Corporation and its subsidiaries design and
manufacture all of their products so they can be operated safely.
However, the responsibility for safe operation rests with those who
use and maintain these products. The following safety precautions
are offered as a guide which, if conscientiously followed, will
minimize the possibility of accidents throughout the useful life of
this equipment.
The compressor should be operated only by those who have been
trained and delegated to do so, and who have read and understood
this Operator's Manual. Failure to follow the instructions,
procedures and safety precautions in this manual can result in
accidents and injuries. Read this manual prior to installation, start
up and maintenance.
NEVER start the compressor unless it is safe to do so. DO NOT
attempt to operate the compressor with a known unsafe condition.
Tag the compressor and render it inoperative by disconnecting and
locking out all power at source or otherwise disabling its prime
mover, so others who may not know of the unsafe condition,
cannot attempt to operate it until the condition is corrected.
Install, use and operate the compressor only in full compliance
with all applicable Federal, State and local codes, standards and
regulations.
DO NOT modify the compressor and/or controls in any way
except with written factory approval.
1.2 PERSONAL PROTECTIVE EQUIPMENT
Prior to installing or operating the compressor, owners, employers
and users should become familiar with, and comply with, all
applicable regulations and any applicable Federal, State and Local
codes, standards and regulations relative to personal protective
equipment such as eye and face protective equipment, respiratory
protective equipment, equipment intended to protect the
extremities, protective clotching, protective shields and barriers
and electrical protective equipment, as well as noise explosure
administrative and/or engineering controls and/or personal hearing
protective equipment.
1.3 PRESSURE RELEASE
A. Install an appropriate flow limiting valve between the service
air outlet and shut off valve, either at the compressor or at any
other point along the air line, when an air hose exceeding 13
mm(1/2") inside diametre is to be connected to the shut off
valve to reduce pressure in case of hose failure, Per all
applicable federal, state and local codes, standards and
regulations.
B. When the hose is to be used to supply a manifold, install an
additional appropriate flow-limiting valve between the
manifold and each air hose exceeding 13 mm(1/2") inside
diametre that is to be connected to the manifold to reduce
pressure in case of hose failure.
C. Provide an appropriate flow limiting valve at the beginning of
each additional hose in runs of air hose exceeding 13 mm insid
ediametre to reduce pressure in case of hose failure.
D. .Flow limiting valves are listed by pipe size and rated
cbm/min. Select appropriate valves accordingly in accordance
with their manufacturer's recommendations.
E. DO NOT use air tools that are rated below the maximum
rating of the compressor. Select air tools, air hoses, pipes,
valves, filters and other fittings accordingly. DO NOT exceed
manufacturer's rated safe operating pressures for these items.
F. Secure all hose connections by wire, chain or other suitable
retaining devices to prevent tools or hose ends from being
accidentally disconnected and expelled.
G. Open oil filter cap only when compressor is not running and
is not pressurized. Shut down the compressor and bleed the
separator tank (receiver) pressure (P1) to zero internal pressure
before removing the cap (see the sep. tank pressure is 0 from
the pressure gauge by toggling the ∆p control button.). In order
to prevent any burnings and injuries, wait for reducing of the
oil foams in the separator tank after compressor is shut down.
H. Vent all internal pressure prior to opening any line, fitting,
hose, valve, drain plug, connection or other component such as
filters and line oilers.
I. Keep personal out of line with and away from the discharge
opening of hoses or tools or other points of compressed air
discharge.
1.4 FIRE AND EXPLOSION
A. Clean up spills of lubricant or other combustible substances
immmediately, if such spills occur.
B. Shut off the compressor and allow it to cool. Then keep sparks,
flames or other sources of ignition away and DO NOT permit
smoking in the vicinity when checking or adding lubricant.
C. DO NOT permit oils or oil film to accumulate on, under or
around acoustical material, or on any external surfaces of the
air compressor or on internal surfaces of the enclosure. Wipe
down using an aqueous industrial cleaner or steam-clean as
required.If necessary remove acoustical material, clean all
surfaces and replace acoustical material. Any acoustical
material with a protective covering that has been torn or
punctured should be replaced immediatelly to prevent
accumulation of the liquids or oil film within the material. DO
NOT use flammable solvents for cleaning purposes.
D. Disconnect and lock out all power at source prior to attempting
any repairs or cleaning of the compressor or of the inside of the
enclsure if any.
E. Keep electrical wiring,including all terminals and presssure
connectors in a good condition. Replace any wiring that has
cracked, cut abraded or otherwise degraded insulation, or
terminals that are worn, discolored or corroded. Keep all
terminals and pressure connectors clean and tight.
F. Keep grounded and/or conductive objects such as tools away
from exposed live electrical parts such as terminals to avoid
arching which might serve as a source of ignition.
G. Remove any acoustical material or other material that may be
damaged by heat or that may support combustion and is in
close proximity, prior to attempting weld repairs.
H. Keep suitable fully charged fire extinguisher or extinguishers
nearby when servicing and operating the compressor.
I. Keep oil rags, trash, leaves,litter or other combustibles out of
and away from the compressor.
J. DO NOT operate the compressor without proper flow of
cooling air or with inadequate flow of lubricant or with
degraded lubricant.
K. DO NOT attempt to operate the compressor in any
classification of hazardous environment unless the compressor
has been specially designed and manufactured for that duty.
1.5 MOVING PARTS
A. Keep hands, arms or other parts of the body and also clotching
away from drive couplings, fans and other moving parts.
B. DO NOT attempt to operate the compressor with the fan,
coupling or other guards removed.
C. Wear snug-fitting clotching and confine long hair when
working around this compressor, especially when exposed to
hot or moving parts.
D. Keep access doors, if any, close except when making repairs
and adjustments.
E. Make sure all personal are out of and/or clear of the
compressor prior to attempting to start or operate it.
F. Disconnect and lock out all power at source and verify at the
compressor that all circuits are de-energized to minimize the
possibility of accidential start up or operation, prior to
attempting repairs or adjustments. This is especially important
when compressor are remotely controlled and remote control
must be shown by signs and decals that are visible from each
point of compressor
G. Keep hands, feet, floors, controls and walking surfaces clean
and free of oil, water or other liquids to minimize the
possibility of slips and falls.
H. Provide an adeqous illuminazition where the compressor is
installed.
1
 1.SAFETY
1.6 HOT SURFACES, SHARP EDGES AND SHARP
CORNERS
A. Avoid body contact with hot oil, hot coolant, hot surfaces and
sharp edges and corners.
B. Keep all parts of the body away from all points of air
discharge.
C. Wear personal protective equipment including gloves and head
covering when working in, on or around the compressor.
D. Keep a first aid kit handy. Seek medical assistance promptly in
case of injury. DO NOT ignore small cuts and burns as they
may lead to infection.
1.7 TOXIC AND IRRITATING SUBSTANCES
A. DO NOT use air from this compressor for respiration
(breathing) except in full compliance with any Federal, State or
Local codes or regulations.
DANGER!
Death or serious injury can result from inhaling compressed
air without using proper safety equipment.
B. DO NOT use compressed air in air lines supplying respirators
or other breathing air utilization equipment and DO NOT
discharge air from these systems in unventilated or other
confined areas.
C. Operate the compressor only adequately ventilated areas.
D. Locate the compressor or provide a remote inlet so that it is not
likely to ingest exhaust fumes or other toxic, noxious or
corrosive fumes or substances.
E. Coolants and lubricants used in this compressor are typical of
the industry. Care should be taken to avoid accidental ingestion
and/or skin contact. In the event of ingestion, seek medical
treatment promptly. Wash with soap and water in the event of
skin contact. Consult the compressor operator's manual
lubrication section for information pertaining to compressor oil
fill.
1.8 ELECTRICAL SHOCK
A. This compressor should be installed and maintained additional
to this manual in full compliance with all applicable Federal,
State and Local codes, standards and regulations, including
those of the National Electrical Code and also including those
relative to equipment grounding conductors and only by
personal that are trained, qualified and delegated to do so.
B. Keep all parts of the body and any hand-held tools or other
conductive objects away from exposed live parts of electrical
system. Maintain dry footing, stand on insulating surfaces and
DO NOT contact any other portion of the compressor when
making adjustments or repair to exposed live parts of the
electrical system. Make all adjustments and repairs with one
hand only-if possible with the right hand-, so as to minimize
the possibility of creating a current path through the heart.
C. Attempt repairs in clean,dry and well lightened and ventilated
areas only.
D. DO NOT leave the compressor unattended with open electrical
enclosures. If necessary to do so, then disconnect, lock out and
tag all power at source so others will not inadvertendly restore
power.
E. Disconnect, lock out and tag all power at source prior to
attempting repairs or adjustments to rotating machinery and
prior to handling any ungrounded conductors.
F. Dry test all shut down circuits prior to starting the compressor
after installation.
1.9 LIFTING AND HANDLING
A If the compressor is provided with a lifting bail, then lift by the
bail provided. If no bail is provided, then lift by sling as shown
in figure 1.1.Compressors to be air lifted by helicopter must
not be supported by the lifting bail but by slings instead. In any
event, lift and/or handle only full compliance with Federal,
State and Local codes.
B. Inspect points of attachment for cracked welds and for cracked,
bent, corroded or otherwise degraded members and for loose
bolts or nuts prior to lifting.
C. Make sure entire lifting, rigging and supporting structure has
been inspected, is in good condition and has a rated capacity of
at least the weight of the compressor. If you are unsure of the
weight, then weight compressor before lifting.
D. Make sure lifting hook has a functional safety latch or
equivalent, and it is fully engaged and latched on the bail or
slings.
E. Use guide ropes or equivalent to prevent twisting or swinging
of the compressor once it has been lifted clear of the ground.
F. DO NOT attepmt to lift in high winds.
G. Keep all personal out from under and away from the
compressor whenever it is suspended.
H. Lift compressor no higher than necessary.
I. Keep lift operator in constant attendence whenever compressor
is suspended.
J. Set compressor down only on a level surface capable of safely
supporting at least its weight and its loading unit.
K. When moving compressor by forklift truck, utilize fork pockets
if provided. Otherwise, utilize pallet if provided.If neither fork
pockets or pallet are provided, then make sure compressor is
secure and well balanced on forks before attempting to raise or
transport in any significant distance.
L. Make sure forklift truck forks are fully engaged and tipped
back prior to lifting or transporting the compressor.
M. Forklift no higher than necessary to clear obstacles at floor
level and transport and corner at minimum practical speeds.
N. Make sure pallet mounted compressors are firmly bolted or
otherwise secured to the pallet prior to attempting to forklift or
transport them.NEVER attempt to forklift a compressor that is
not secured to its pallet, as unev en floors or sudden stops may
cause the compressor to tumble off, possibily causing serious
injury or property damage in the process.
O. DO NOT use the lifting eye bolt on the compressor motor, if
supplied, to lift the entire compressor package.
Figure 1.1: LIFTING and HANDLING
1.10. ENTRAPMENT
A. If the compressor enclosure is large enough to hold a person
and if it is necessary to enter it to perform service adjustments,
inform other personel before doing so,or else secure and tag
the access door in the open position to avoid the possibility of
others closing and possibly latching the door with personel
inside.
2
 2.INSTALLATION
2.1 LOCATION OF COMPRESSOR
The EKO Series compressor package may be placed on any level
surface capable of supporting its weight and rigid enough to
maintain a level compressor frame. Level and compressor
alignment is required. Floor must be protected from humidity and
oil leakage which may cause to burns and corrosions. No piping
loads shall be transmitted to the compressor at the external
connections. Proper room and location is shown in Figure 2.1.For
outside location please consult the factory.
Figure 2.1: INSTALLATION
2.2 VENTILATION AND COOLING
Select a location to permit sufficient unobstructed air flow in and
out of the compressor to keep the operating temperature stable. The
minimum distances from the compressor must be proper to
maintenance and cooling requirements. Compressor must be
installed according to dimensional drawings and also, additional
‘Ekomak Screw Compressors Installation Principles’ document. In
order to prevent excessive ambient temperature rising, it is
imperative to provide adequate ventilation. DO NOT instal the
compressor where it will be exposed to temperature less than 0 °C’
or heat the compressor room as required.
2.3. SERVICE AIR PIPING
Service air piping should be installed as shown in Figure 2.1. A
shut off valve should be installed to isolate the compressor from
the service line. Also notice that the service line should be
equipped with the condensate drains throughout the system.
2.4. OIL LEVEL CHECK
To check oil level correctly, please run the compressor till the oil
temperature rises to 90ºC then stop it and observe the oil level in
the sigh glass or the transparent tube and level sign label behind it.
The oil level must be in max. and min. limits. If oil level is low,
add oil up to the correct level. Do not fill oil above max. oil level
sign/line. (Please read Mainteneance section for details…)
2.5. ELECTRICAL PREPARATION
Electrical wires must be selected and connected according to rated
current values of the compressor as mentioned by the standards.
Connections must be performed by the qualified electric
technicians. Manufacturer will provide all the technical datas and
diagrams to the user.
NOTE !
Customer must provide electrical supply power disconnect
within sight of machine.
A few electrical checks should be made to help assure that the first
start-up will be trouble-free.
WARNING !
Lethal shock hazard inside. Disconnect all power at source
before opening and servicing.
1. Check incoming voltage. Be sure that compressor is wired for
the correct incoming voltage.
2. Check all electrical connections for tightness.
3. Operate the compressor to check the motor rotation direction
control for a short time(1-2 sec) as explained in section 2.6.
NOTE !
Wiring diagram for standard compressors is supplied on the
inside cover of the Control Center.Optional compressor wiring
diagrams will vary.
2.6. MOTOR ROTATION DIRECTION CHECK
NOTE!
Motor rotation check must be made at compressor start up. As
needed, remove compressor panel to view motor rotation.
COMPRESSORS EQUIPPED WITH ELECTRO-MECHANIC
CONTROL
Press “READY” button and see the light is on. After you release
this button, if the light remains on, you can run the compressor. If
the light is off, that means, the phases (R,S,T) are connected
wrong. Disconnect the power and change the position of 2 phases.
To check it again, please look at the motor protection relay in the
electrical cabinet. If the light of this relay is on, that means the
compressor is ready to start. A "Direction of Rotation" decal is
located on the motor to show proper motor/compressor rotation.
(see figure 2.2)
Figure 2.2: DIRECTION OF ROTATION
COMPRESSORS EQUIPPED WITH ELECTRONIC CONTROL
Energise the compressor. If the control panel is energised and if
there is no alarm (Er:0020) on the screen that means you can run
the compressor. But if the panel is not energised or if you face
Er:0020 fault, that means the phases (R,S,T) are connected wrong
Disconnect the power and change the position of 2 phases. To
check it again, please look at the motor protection relay in the
electrical cabinet. If the light of this relay is on, that means the
compressor is ready to start. A "Direction of Rotation" decal is
located on the motor to show proper motor/compressor rotation.
(see figure 2.2)
3
 3. SPECIFICATIONS

3.1. TECHNICAL SPECIFICATIONS

COMPRESSOR TYPE : ………………………………………..

WORKING PRESSURE : 7 bar 8 bar 10 bar 13 bar
CAPACITY : ..................... m3/min
DRIVE TYPE : Direct Drive Gear Drive
START SYSTEM : Star-Delta Inverter Driven
AIR END TYPE : ...............................................................
COOLING SYSTEM : Air Cooled
AMBIENT TEMPERATURE : 0-45 ºC
AVERAGE WORKING TEMP. : 82-96 ºC
DELIVERY AIR TEMPERATURE : 8-12 ºC above ambient
INVERTER : ...............................................................
MAIN MOTOR : 380/400 V, 50/60 Hz, ……… RPM, ……… kW, ……….. A
FAN MOTOR : 380/400 V, 50/60 Hz, ……… RPM, ……… kW, ……….. A
FAN DIAMETER : …………... mm ………….……..……
FAN CAPACITY : …………… m3/h ………. Pa
COOLING CAPACITY : ………….... kcal/h
RECOMMENDED OIL : ………………………………………… (The first filling type of oil.)
EQUIVALENT OILS : …………………………………………
OIL CAPACITY : .................... L ……………...…….……
OIL FILTER : …………………………………..……..
AIR INLET FILTER : …………………………………..……..
COUPLING : …………………………………..……..
SEPARATOR ELEMENT : …………………………………..……..
SAFETY PRESSURE SWITCH : …………………………………..……..
WORKING PRESSURE SWITCH : …………………………………..……..
PRESSURE SENSOR : …………………………………..……..
TEMPERATURE SENSOR : …………………………………..……..

3.2 LUBRICATION GUIDE Ekomak encourage the user to participate in a lubricant analysis
For best value and longest uninterrupted service, the EKO program. This could result in an oil change interval that is
compresssors are factory filled and tested with a long life different from those stated in this manual. Contact your Ekomak
lubricant. MIXING OF OTHER LUBRICANTS WITHIN dealer for details.
THE COMPRESSOR WILL VOID ALL WARRANTIES. Maintenance of all other components is still recommended as
If due to availability or other reasons, other oils are required, indicated in the Operator's Manual
follow lubrication guide from EKOMAK.
For light duty, high humidity service where condensed moisture
and emulcification (mayonnaise) may occur, the oil change
interval must be reduced to 300 hours maximum. A non-
detergent oil with rust, oxidation and foam inhibitors and good
water separation characteristics should be used.
Mixing of non-detergent mineral oils with detergent oils may
lead to operational problems such as foaming, filter plugging
orifice or line plugging.
When ambient conditions exceed those noted or if conditions
warrant use of "extended" life lubricants contact Ekomak for
recommendation.

4
 4.COMPRESSOR SYSTEMS
4.1 INTRODUCTION
Your new Ekomak oil injected rotary screw air compressor will
provide you with improved reliability and greatly reduced
maintenance.
4.2 DESCRIPTION OF COMPONENTS
The components and assemblies of the EKO D and EKO GD
compressors consist of a compressor unit (air end), electric
motor, starter, air inlet system, compressed air discharge system,
oil/air separation system, compressor lubrication and cooling
system, instrument panel, all mounted in a strong cabinet.
On these compressors, compressor unit (air end) which is being
turned by motor draws the air, presses it by the oil film and sends
to the separator tank (receiver). Separator element separates the
air from the oil. Oil which is cooled in the oil/air cooler bleeds
back through the compressor unit and the compressed air is being
sent for usage. A fan draws air over the motor and forces it out
through the combine aftercooler and oil cooler for removing the
compression heat from the compressed air and the oil.
The compact design of the EKO D and EKO GD Series air
compressor provides easy access to all servicable components
such as the oil filters and control valves.
The inlet air filter is also easy accessible for servicing.
4.3 COMPRESSOR UNIT, FUNCTIONAL
DESCRIPTION
Ekomak air compressors feature the compressor unit, a single
stage, positive displacement, oil-injected-type compressor. This
unit provides continuous pulse-free compression to meet your
needs.
NOTE !
With an Ekomak compressor, there is no maintenance or
inspection of the internal parts of the compressor unit (air
end) permitted in accordance with the terms of the warranty.
In the event a change of oil is required, use only recommended
lubricant (by Ekomak).
WARNING ! !
MIXING OF OTHER LUBRICANTS WITHIN THE
COMPRESSOR UNIT WILL VOID ALL WARRANTIES!.
4.4. COMPRESSOR COOLING AND LUBRICA-
TION SYSTEM, FUNCTIONAL DESCRIPTION
The cooling system consists of a fan, fan motor, an oil/air cooler,
oil filter, thermostatic valve, interconnecting piping and tubing
and separator tank. The pressure in the receiver (separator tank)
causes oil flow by forcing the oil from the high pressure area of
the sump to a lower pressure area in the compressor unit. Oil
flows from the bottom of the receiver/sump to the thermostatic
valve. The thermostatic valve is fully open when the temperature
is below 72 °C. Then the oil passes through the thermostatic
valve, the main filter and directly to the compressor unit when it
lubricates,cools and seals the rotors and the compressor chamber.
As the discharge temperature rises above 72 °C, due to the heat
of compression, the thermostatic valve begins to close and a
portion of the oil then flows through the cooler. From the cooler
the oil flows to main filter and then on to the compressor unit.
A portion of the oil flowing to the compressor is routed to the
anti-friction bearings which support the rotors in the compressor
unit. Prior to entering the compressor unit, this oil is taken
through oil filter, thus assuring properly filtered lubricant for
bearing supply.
Oil is injected into the compressor unit in large quantities and
mixes directly with the air as the rotors turn compressing the air.
The oil flow has three basic functions:
1. As coolant, it controls the rise of air temperature normally
associated with the heat of compression.
2. Seals the leakage paths between the rotors and the stator and
also between the rotors themselves.
3. Acts as a lubricating film between the rotors allowing one
rotor to directly drive the other, which is an idler.
After the air/oil mixture is discharge from the compressor unit,
the oil is separated from the air.At this time, the air flows through
an aftercooler then to your service line while the oil is being
cooled in preparation for reinjection.
4.5 COMPRESSOR DISCHARGE SYSTEM,
FUNCTIONAL DESCRIPTION
The compressor unit discharges the compressed air/oil mixture
into the receiver/sump. The receiver has three basic functions:
1. Acts as a primary oil separator.
2. Serves as the compressor oil sump.
3. Houses the final oil separator.
The compressed air/oil mixture enters the receiver and is directed
toward the bottom of separator element as the compressed air
flows through the separator. The velocity of the mixture is
reduced and changed its direction. Thus, this allows oil to
combine and to flow thruogh the bottom of the compressor. In
this phase, the oil rate in the oil/air mixture is reduced.
This mixture is directed to the separator filter. Separator, with its
special form, holds the oil particules moving by velocity of air
and separates oil from the air. Meanwhile, some of oil leaks into
the separator. This amount of oil will be returned through the
compressor unit by collecting from oil return line.A return line
(or scavenge tube) leads from the bottom of the separator element
to the inlet region of the compressor unit. Oil connecting on the
bottom of the separator is returned to the compressor by a
pressure differential between the receiver and the compressor
inlet. A visual sight glass is located on the return line to observe
this oil flow. THIS FLOW MUST BE CHECK
PERIODICALLY. There is also an orifice (protected by a
strainer), a check valve to prevent adversly flow and connection
pipes in this return line to assure proper flow.
The life of the separator can be understood with periodical
inspections by checking the pressure differance between the line
pressure and internal pressure (P2 and P1). When the compressor
is on load and above 5 bar, the differential must be less than 1.2
bar. If the pressure difference is over 1.2 bar, then separator
element must be changed. If safety pressure switch stops the
compressor frequently then separator must be checked.
A minimum pressure check valve, located downstream of the
separator, assures a minimum receiver pressure of 3.8 bar during
all conditions. This pressure is necessary for proper air/oil
separation and proper oil circulation. A terminal check valve is
incorporated into the minimum pressure check valve to prevent
compressed air in the service line from bleeding back into the
receiver on shut down and during operation of the compressor in
an unloaded condition. If the service line pressure is less than 3.8
bar, during initial start up, minimum pressure check valve limits
the separator tank pressure at 3.8 bar until the service line
pressure is equal to the separator tank pressure.
A pressure relief (safety) valve is set to open if the separator tank
pressure exceeds the separator tank rating. A temperature switch
will shut down the compressor if the discharge temperature
reaches 115°C.
WARNING !
DO NOT remove caps, plugs or other components when
compressor is running or pressurized.
Stop compressor and relieve all internal pressure before
doing so.
Oil is added to the sump via a capped oil filler opening, placed
low on the tank to prevent overfilling of the separator tank.
5
 4.COMPRESSOR SYSTEMS
4.6. CONTROL SYSTEM,
FUNCTIONAL DESCRIPTION
EKO D and EKO GD SERIES:
The purpose of the compressor control system shown in Figure
4.1 is to regulate the compressor air intake to match the amount
of the compressed air being used. When the pressure reaches to
required maximum pressure, the control system will
automatically blowdown the compressor and greatly reduce the
unload power consumption. The control system consists of an
inlet valve, solenoid valves and a pressure switches. The
functional description of the control system is given below in
four distinct phases of compressor operation.
START-0 to 3.8 bar
When the compressor’s START button is turned, the separator
tank pressure will quickly rise from 0 to 3.8 bar. During this
period, the inlet valve is open. Control and by pass solenoid
valves are fully open due to inlet air flow and the compressor
pumps at the full rated capacity. The rising compressor air
pressure is isolated from the service line in this phase by the
minimum pressure valve, set at approximately 3.8 bar .
NORMAL OPERATING MODE- 3.8 to 8/10/12 bar
When the pressure air rises above 3.8 bar. The minimum pressure
check valve opens and delivers compressed air to the service line.
From this point, the line air pressure is continually monitored by
a pressure gauge. The pressure switch and the blown down valve
remain closed during this phase. The inlet valve remains fully
open for maximum capacity.
Figure 4.1: CONTROL SYSTEM (STANDARD CONTROL PANEL)
UNLOAD-IN EXCESS OF 8/10/12 bar LINE PRESSURE
When no air is being used, the service line pressure rises to the
setting (cut out pressure) of the pressure switch, the pressure
switch opens, interrupting the electrical power to the solenoid
valve. At this time, the solenoid valve allows dry separator tank
air pressure to be applied directly to the inlet valve piston and
keep it closed. The solenoid valve starts an internal circulation by
directing the air in the separator tank to the inlet region of the
compressor unit for the continouing the compressor’s oil
circulation. Compressor will go on its cooling and lubricating
process by circulating the air there, in the unload position.By
pass solenoid valve will discharge the more air for separator tank
pressure reachs at desired unload operation pressure by opening
when the compressor is in unload position. After the closing of
the inlet valve in the unload position of the compressor, the check
valve in the air service line prevents line pressure from returning
to the separator tank. When the line pressure drops to the low
setting (cut in pressure) of the pressure switch, the pressure
switch closes by re-energizing the solenoid valve. The re-
energized solenoid valve again prevents pressure from reaching
the inlet valve. The inlet valve is fully open and the compressor
delivers full rated capacity.
AUTO OPERATING MODE (DUAL CONTROL)
If air requirements varies during unload operation, AUTO
operation mode can be utilized. If the compressor runs about 6
minutes in unload mode then compressor can be shut-down by
toggling the SELECTION BUTON in the instrumental panel to
the AUTO Position. The compressor that is in unload position on
AUTO mode, operates in full rated capacity again if the service
line pressure is mimimum.
6
 4.COMPRESSOR SYSTEMS
EKO DVST and EKO GDVST SERIES:
EKOMAK DVST and GDVST series screw air compressors use
variable speed drive system for capacity control/modulation. If
the working pressure (at the outlet of the compressor) is below
the target (load) pressure set point, the compressor runs with the
maximum speed to meet compressed air demand. If compressed
air consumption is less than the compressor capacity, pressure
increases and the control system (and the inverter) reduces motor
speed (frequency) to keep working pressure as constant, at the
target (load) pressure setpoint. If the working pressure reaches to
the maximum working pressure (unload) setpoint, already
main/drive motor speed is reduced to the minimum speed, the
control system unloads the compressor by closing the inlet valve.
If compressed air comsumption/demand continues to be under
compressed air flow rate of the compressor, just after 3 minutes
or another idle (stand by run on) time set value, the control
system stops the compressor and passes it to the stand by mode.
When the compressed air system pressure decreases to the target
(load) pressure setpoint, the compressor automaticaly re-starts.
START - 0 to 3.8 bar
When the compressor START button is pressed, the separator
tank pressure will quickly rise from 0 to 3.8 bar. During this
period, the inlet valve is open. Inlet valve is fully open and the
compressor pumps at the full rated capacity while the main motor
is running/turning with maximum speed. The rising compressor
air pressure is isolated from the service line in this phase by the
minimum pressure valve, set at approximately 3.8 bar .
NORMAL OPERATING MODE - 3.8 to 8/10/12 bar
When the pressure air rises above 3.8 bar, The minimum pressure
check valve opens and delivers compressed air to the service line.
Up to target (load) pressure set point, the control system runs the
compressor on load (the inlet valve is full open) with maximum
motor speed. When the working pressure approaches to the
maximum working (unload) pressure setpoint, inlet valve
remains fully open while control system reducing motor speed to
keep compressed air flow as equal to compressed air demand at
tthe target (load) pressure set point. The control system reduces
capacity down to the minimum capacity by the minimum motor
speed, if compressed air demand continues to be less than
compressor capacity.
UNLOAD-IN EXCESS OF 8/10/12 bar LINE PRESSURE
While compressor is running with the minimum motor speed, if
the compressed air demand is less than the compressor capacity,
the control system unloads compressor by closing inlet valve by
using the unloader (control) solenoid valve. The control system
uses standby run-on timer for idle/unload running duration, when
idle running duration (standby run on time) becomes equal to idle
(stand by run-on) time set point without any compressed air
demand rising, the control system stops the compressor and
passes it to th standby mode (in “ready to start” condition). When
the compressed air system (network) pressure decreases to the
target (load ) pressure, compressor automatically restarts, while it
is in the standby mode.
At the unload running time, the control solenoid valve is closes
the inlet valve and the blowdown (bypass) solenoid valve opens
and releases the separator tank (receiver, sump) pressure to
atmosphere by reverse flow through air intake line. A unload
running pressure setpoint is kept for continuoing the
compressor’s oil circulation and control air supply.
4.7. AIR INLET SYSTEM FUNCTIONAL
DESCRIPTION
The compressor inlet system consists of a dry type air filter and
an air inlet valve as shown in figure 4.2.
The air inlet valve directly controls the amount of air intake to
the compressor in response to the operation of the pressure
switch. The inlet valve also acts as a check valve, thus preventing
reverse rotation when the compressor is shut down.
Figure 4.2: AIR INLET SYSTEM
4.8. INSTRUMENT PANEL GROUP,
FUNCTIONAL DESCRIPTION
NOTE: If your compressors are equipped with electronic
control system, please read the electronic control panel
manual for the section 4.8 and 4.9.
Panel group consists of a complete panel as shown the
instruments on the panel in Figure 4.3.
On the instrument panel, there are start-stop, selection buttons,
discharge temperature gauge, reset push button, emergency stop
button, power on light, hourmeter, warning lights, pressure gauge
and the ∆P control button close to the panel.
1. Service line pressure gauge(P2) is connected to the dry side
of the receiver downstream from the check valve and
continually monitors the air pressure in the service line.If the
∆p control button is unpressed then service line pressure
appears. When press the button, internal pressure in the
separator tank can be read. When the compressor is in load
position and is working above 5 bar, the life of the separator
can be understood by pressing the button.If the differance
between internal and service line pressures is more than 1.2
bar then separator element must be changed.
2. The discharge temperature gauge monitors the temperature
of the air leaving the compressor unit.The normal reading is
approximately 80-110 °C.If temperature rises above 115 °C
then system stops.
3. The START/STOP buttons turns the compressor on/off.
4. The SELECTION button is used to choose the unload and
auto modes (DUAL control).
5. The hourmeter records accumulative hours of operation for
the compressor and useful for planning and logging service
operations.
6. The maintenance lights monitors the conditions of the
instrument which are required for maintenance.
7. M1 indicates that the main motor starter stops the
compressor in case of overloading of motor
8. M2 indicates the fan motor starter stops the compressor in
case of overloading of the fan motor.
9. T1 indicates that the temperature switch stops the compressor
in case of extreme temperature in the compressor unit
10. P1 indicates that the pressure switch stops the compressor in
case of extreme pressure in the separator tank.
11. The EMERGENCY STOP push button shuts down the
compressor in emergency.
12. The POWER ON light announces that there is electricity in
the system.
7
 4. COMPRESSOR SYSTEMS
Figure 4.3: INSTRUMENT PANEL GROUP
4.9. PURPOSE OF CONTROLS
CONTROL OR INDICATOR
START-STOP BUTTON
SELECTION BUTTON
EMERGENCY STOP
HOURMETER
LINE PRESSURE GAUGE
∆P CONTROL BUTTON
DISCHARGE TEMPERATURE GAUGE
"POWER ON" LIGHT (GREEN)
"OVERLOAD" LIGHT (YELLOW)(M1)
"OVERLOAD" LIGHT (YELLOW)(M2)
"EXTREME TEMPERATURE"LIGHT
(YELLOW)(T1)
"EXTREME PRESSURE" LIGHT
(YELLOW) (P1)
OIL LEVEL SIGHT GLASS
SEPARATOR RETURN LINE SIGHT GLASS
(SCAVENGE LINE)
THERMOSTATIC VALVE
MINIMUM PRESSURE CHECK VALVE
CONTROL SOLENOID VALVE
BLOW DOWN SOLENOID VALVE
PRESSURE SWITCH(SAFETY)
PRESSURE SWITCH (ADJUSTMENT)
PURPOSE
Turn the button to I position to start the compressor and O position to stop the
compressor.
Use to select both MANUAL and AUTO operation modes.To start in the automatic
mode, turn the switch to AUTO clockwise.
Press the button to stop the compressor in emergency.At this time, the button will be
locked.To unlock it, turn the switch counterclockwise.
Records accumulative hours of compressor operation; useful for planning and
logging service schedules.
Continually monitors service line air pressure.
Check to ensure that there is no pressure in the service line when the compressor is
starting initial
Monitors temperature of the air leaving the compressor unit.The normal reading
should be approximately 80 to 110 °C. Contacts are set to 115 °C.
Indicates when the starter is receiving power.
Indicates when main motor is running on overload.Protection relay will stop the
compressor.
Indicates when the fan motor is running on overload.
Indicates when the operating temperature rises above the setting temperature and
temperature switch will shut down the compressor.
Indicates when the operating pressure rises above the setting pressure.Safety
pressure switch will shut down the compressor.
Shows the oil level in the separator tank. Oil must be observing easily. Check the
level when the compressor is not running.Level should not exceed the filling surface
to prevent the overflow.
Used to indicate oil flow in the return line.When the compressor is running at full
load,oil flow should be visible in this sight glass.There may be little or no flow when
the compressor is running unloaded,but a sluggish flow at full load indicates a need t
clean the return line strainer.
Regulates flow of oil to and around the cooler. It is designed to maintain a minimum
operating temperature of 77 °C. It is used for fast warm up on start up.
Maintains minimum of 3,8 bar in the compressor’s separator tank. Valve piston
restricts receiver air discharge from the separator tank when line pressure falls to 3,8
bar.Also prevents backflow into the separator tank during unload conditions and
after shut down.
When the compressor pressure is above the setting pressure, closes inlet valve.
Discharges the compressed air in the separator tank.
Stops the system when the pressure switch (adjustment) and the inlet system are
defected. After checking the system, press red RESET button to restart the
compressor.
Senses service line pressure. When line pressure reaches maximum/minimum
setting the pressure switch sends signal to the solenoid valves to unload/load the
compressor.
8
 5. OPERATION
5.1. GENERAL
While Ekomak has built into this compressor a comprehensive
array of controls and indicators to assure you that it is operating
properly, you will want to recognize and interpret the reading
which will call for service or indicate the beginning of a
malfunction. Before starting your compressor, read this section
thoroughly and familiarize yourself with the controls and
indicators and their purpose, location and usage.
NOTE: If your “EKO” compressors are equipped with
electronic controller (EKOMASTER II, S1, S1-10, M6, P1,
L1 control panels or another one), or your compressor is a
VST compressor (with EKOMASTER V, R1 control panels
or another one), please read the electronic controller manual
in addition to following instructions.
5.2. INITIAL START-UP PROCEDURE
EKO D and EKO GD series, with standard control panel:
The following procedure should be used to make the initial start
up of the compressor:
1. Read the preceding pages of this manual thoroughly.
2. Take off and scrap the two red colered metallic braket.
3. Be sure that all preparations and checks described in the
installation section have been made.
4. Open the shut off valve to the service line.
5. Energize the starter. See the POWER ON light is on.
6. See the reset light is on by pressing the reset button. If the
light is on then, compressor is ready to operate.
7. Start the compressor by turning the START button to
START (I) position.
8. Check motor rotation direction.
9. Check for possible oil/air leaks in piping inside and outside
the compressor.
10. Slowly close the shut off valve and check that the setting on
the pressure switch is set correctly.If set correctly,the
compressor will unload at the desired unload pressure also
check safety pressure setting. If adjustments are necessary,
see Control System Adjustments in the Maintenance Section
of the manual.
11. Observe the maintenance lights and signals on the panel and
ensure the operating pressure, operating temperature.
12. Observe the operating temperature. If the operating
temperature exceeds 110°C, the cooling system or installation
environment should be checked.
13. Observe return line sight glass and maintenance indicators.
14. Open shut off valve to service line.
15. Reinspect the compressor for temperature and leaks the
following day.
EKO DVST and EKO GDVST series, with electronic control
panel:
The following procedure should be used to make the initial start -
up of the compressor:
1. Read the preceding pages of this manual thoroughly.
2. Take off and scrap the two red colered metallic braket.
3. Be sure that all preparations and checks described in the
installation section have been made.
4. Open the shut off valve to the service line.
5. Energize the starter. See the compressor’s controller display
(control panel) shows READY TO RUN status. (There is no
any fault or start inhibit signal/message etc.)
6. If the compressor is ready to run, start the compressor by
pressing the START button.
7. Check motor rotation direction.
8. Check for possible oil/air leaks in piping inside and outside
the compressor.
9. Slowly close the shut off valve and check that the setting of
the working pressure is set correctly. If it is set correctly, the
compressor will unload at the desired unload pressure also
check safety pressure setting.
If adjustments are necessary, read the the electronic controller
manual.
10. Observe the maintenance lights and signals on the panel and
ensure the operating pressure, operating temperature.
11. Observe the operating temperature. If the operating
temperature exceeds 96 °C, the cooling system or installation
environment should be checked.
12. Observe return line sight glass and maintenance indicators.
13. Open shut off valve to service line.
14. Reinspect the compressor for temperature and leaks the
following day.
Figure 5.1: ELECTRONIC CONTROL PANEL (R1)
START (green, 1): Enter STARTED condition
STOP (red, 0) : Exit STARTED condition
RESET: Reset and clear fault conditions
ENTER: Confirm selection or value adjustments
MINUS/DOWN: Scroll down through menu, menu item
options or decrement value
PLUS/UP: Scroll up through menu, menu item options or
increment value
ESCAPE: Step back one menu navigation level
MENU: Initiate access code entry
* START and STOP have one defined function and are not used
for any other purpose.
* RESET will initiate a display jump to the fault code item if a
fault condition remains active or initiate a display jump to the
information item if no active faults exist in normal display mode.
If pressed and held for longer than two seconds in menu mode
will exit menu mode to the normal operational display mode.
* ESCAPE will initiate a display jump to the information item in
normal display mode, page 00.
* PLUS, MINUS, ENTER and ESCAPE are used to navigate menu
mode and adjust menu parameters.
(Please, read the controller manual for more information
about the Ekomaster Controller & Operator Panel.)
5.3 SUBSEQUENT START-UP PROCEDURE
On subsequent start-ups, check that the proper level is in the
separator tank and turn the START button to START (I) position
(on electromechanic control panel) or simply press the START
button (on electronic control panel). When the compressor is
running, observe the instrument/control panel. Also observe the
oil flow in return line sight glass.
5.4 SHUTDOWN PROCEDURE
To shut the compressor down, simply turn the START button (on
electromechanic control panel) to STOP (0) position or press
STOP button (on electronic control panel).
9
 6.MAINTENANCE
6.1. GENERAL
WARNING!
Before doing compressor maintenance, disconnect
compressor from power source and lock out power source.
Isolate compressor from line pressure by closing
recommended discharge shut off valve and be sure internal
pressure has blown down to zero.
As you proceed in reading this section, it will be easy to see that
the Maintenance program for the air compressor is quite minimal.
Periodical checks and the sevice indicators will alert you when
service maintenance is required. Read carefully before the
maintenance and take care that the maintenance should be
performed by the authorized person. This will increase the
lifetime of your compressor. MAINTENANCE BY THE
UNAUTHORIZED, NON-TRAINED PERSONS AND/OR
WORKSHOPS WITHOUT PROPER ENVIRONMENT
WILL VOID THE WARRANTY AND MAY CAUSE
INJURIES AND ACCIDENTS.
If any inquiries in spite of the instructions in this manual
please do not hesitate to contact the nearest authorized
technical service.
NOTE: Please conform to national and local laws and
regulations for effluent oil & condensate removal procedures.
6.2. DAILY OPERATION
Prior to starting the compressor, it is necessary to check the oil
level in the sump. Should the level be low, simply add the
necessary amount. If the addition of the oil becomes too
frequent,a simple problem has developed which is causing this
excessive loss.See the Troubleshooting Section under Excessive
Oil Consumption for a probable cause and remedy.
After a routin start has been made, observe the instrumental panel
gauges and be sure they monitor the correct reading for this
particular phase of operation. After the compressor has warmed
up,it is recommended that a general check on the overall
compressor and instrumental panel be made to assure that the
compressor is running properly.
WARNING !
DO NOT remove caps, plugs or other components when
compressor is running or pressurized.
Stop the compressor and relieve all internal pressure before
doing so.
6.3. PERIODIC MAINTENANCE
AFTER EVERY 50 HOURS OF OPERATION
(WEEKLY)
Perform the following maintenance operations to prevent
unnecessary problems:
1. Check oil level. Add same type oil into the separator tank, up
to normal/specified oil level, if it is required.
2. Purge condensed water from the bottom of the separator
tank, at least 30 minutes after the compressor is stopped.
3. Clean outside (honeycomb) surfaces of the oil&air cooler by
using air gun/jet.
4. Clean the panel filter.
5. Clean the air inlet filter by using air gun/jet with max. 2 bar
air pressure, from inside to outside (on reverse flow
direction). Be careful against filter damage risk due to air
pressure.
6. Check if there is a leakage in the compressor.
AFTER EVERY 1000 HOURS OF OPERATION
1. Check control air line tubes, change if it is required.
2. Check contacts of motor contactors, change if it is required.
3. Change or clean panel filter.
4. Clean outside (honeycomb) surfaces of the air&oil cooler by
using a non-flammable liquid cleaner.
5. Check the differential pressure before and after separator
element. Change separator element if it is blocked.
6. Clean air inlet filter. Change, if it is required.
7. Check oil hose unions/couplings, for leakage. Tighten any
loose unions/couplings.
AFTER EVERY 2000 HOURS OF OPERATION
1. Purge (completely) and refill oil and replace oil filter, if the
oil replacement period is specified as 2000 hours. See Table
3 at the end of this manual.
2. Change air inlet filter element. Change panel filter if it is not
changed at previous mainteneance period.
3. Check all of electrical power connections. Tighten any loose
connections.
4. Add grease to the motor bearings. See Table 2 at the end of
this manual.
AFTER EVERY 4000 HOURS OF OPERATION
1 . Change the separator element if it is not changed in the last 4000
hours of operation.
Note: Change (Purge and refill) oil during separator element
replacement. Do not run the compressor with new separator
element but dirty oil. Change separator element when it is
blocked, even if it is not used for 4000 hours. Acceptable
pressure loss is max. 1 bar for a separator element.
2. Change the o-ring of the oil filling plug.
3. Change the separator gaskets.
4. Check bolts of the compressor enclosure and frame and bolts of
other components. Tighten any loose bolts.
6.4. OIL MAINTENANCE
Shut down the compressor and relieve all internal pressure. Drain
the separator tank and change the compressor oil by following
the instructions stated in Section 3.2.
Refill the oil up to normal oil level or up to specified oil quantity.
(Oil must be purged when it is hot. Otherwise, the thermostatic
valve restricts oil flow from the cooler and cold oil flows less.)
If you will not fill same type oil, flush the compressor’s oil
system by using new oil but old separator and filter elements for
about 100 hours running. Then, purge the oil, then change oil
filter and separator element and refill new type oil again. If you
will use equivalent oil or same type oil with different viscosity
grade, flushing is not necessary.
Changing the oil type from the recommended oil (by
Ekomak) to another type or mark of oil, will load the risk on
your own responsibility. Ekomak warrants it’s compressors
in specified terms, but this warranty is valid only with
recommended oils, with proper usage and lubrication. Please,
see Table 3 at the end of this manual for recommended oils.
NOTE: If you do not need to run compressor for a long time,
please run the compressor 1 hour long in every week. If you
will not be able to do that, please fill a special protective oil.
To get this oil please consult our factory.
WARNING!
NEVER open oil drain valve when the compressor is running.
Please wait till the compressor relieves all of pressure in the
separator tank when it is stopped.
10
 6.MAINTENANCE
6.5. OIL FILTER MAINTENANCE
Replace your oil filter element and the gasket under any of the
following conditions, whichever occurs first:
1. Every 2000 hours
2. Every 6 months.
3. Every oil replacement.
6.6. SEPARATOR MAINTENANCE
Replace the separator element at the end of every 4000 hours
regularly. The separator element must be replaced when it is
blocked or service hours are expired. DO NOT clean the
separator elements. Always, renew oil and oil filter when you
renew separator element, if oil and oil filter is not almost
new/clean. (Please, read related details on Section 6.3 and 6.4.)
6.7. PARTS REPLACEMENT AND ADJUSTMENT
PROCEDURES
A-OIL FILTER ELEMENT REPLACEMENT
1. Using a strap wrench, remove the old element And gasket.
Clean gasket sealing surface.
2. Apply a light film of oil to the new gasket. Add oil through
the upper surface of the filter element.
3. Hand tighten new element until new gasket is seated in the
gasket groove. Avoid any nicks,cuts or pinches to the gasket.
4. Continue tighten element by hand an additional 1/2 to 3/4
turn. Restart compressor and check for the leaks.
Figure 6.1: OIL FILTER
CAUTION !
To minimize the possibility of filter element rapture, it is
important that ONLY replacement elements identified with the
Ekomak name, and appropriate part number be used and that
substituted element not be used, due to the fact that such filters
may have inadequate or questionable working pressure ratings.
B-AIR FILTER REPLACEMENT (refer to Figure 6.2)
Air filter replacement should be performed every 6 months or
every 2000 hours. If the filter needs to be replaced, order this
element. Below you will find procedures on how to replace the
air filter element.
1. Stop the compressor.
2. Clean exterior of air filter housing.
3. Release tension on cover clamp assembly.
4. Remove element and clean interior of housing using a damp
clotch. DO NOT blow dirt out with compressed air.
5. Replace the element.
6. Reassemble in the reverse order of the disassembly.
Figure 6.2: AIR INLET FILTER
C-ELEMENT INSPECTION
1. Place a bright light inside the element to inspect for damage
or leak holes. Concentrated light will shine through the
element and disclose any holes.
2. Inspect all gaskets and gasket contact surfaces of the
housing. Should faulty gaskets be evident, correct the
condition immediately.
3. If the clean element is to be stored for using later, it must be
stored in a clean container.
After the element has been installed, inspect and tighten all air
inlet connections prior to resuming operation.
D-SEPARATOR ELEMENT REPLACEMENT
(refer to Figure 6.3)
The separator elements must be changed every 4000 hours.
Follow the procedure explained below for separator element
replacement:
1. Stop the compressor. Close the outlet (shut off) valve.
2. Ensure all pressure in the receiver/separator tank is relieved.
3. Disconnect all piping connected to the separator tank’s cover
plate to allow removal.
4. Loosen and remove the the cover plate bolts.
5. Lift the cover plate from the separator tank.
6. Remove the separator element.
7. Inspect the separator tank for rust or dirt. Clean if necessary.
8. Clean the underside of the cover plate, remove any rust or
remaining material, clean the separator tank’s flange surface.
9. Fit the new separator element into the separator tank, by
using new gaskets.
10. Replace the cover plate, washers and bolts. Tighen bolts with
required torque. (For M12 bolts: 95 Nm, for M16 bolts: 229
Nm. Note that these torque values are for 8.8 grade bolts.)
11. Reconnect all piping making sure scavenge line pipe reaches
to 1-6 mm above the bottom of the separator element (Figure
6.5). This will assure proper oil return flow to the air end.
12. Clean the scavenge strainer before restarting the compressor.
Figure 6.3: SEPARATOR TANK
11
 6.MAINTENANCE
E-CONTROL SYSTEM ADJUSTMENT F-OIL RETURN LINE (SCAVENGE) MAINTENANCE
(For electromechanic control system only, refer to Figure 6.4) During the oil/air separation, some amount of oil passes through
Prior to adjusting the control system, it is necessary to determine the separator. The oil is regained to the system by the scavenge
the desired operation pressure range and also the maximum line. When the compressor running at full load, oil flow should
pressure at which your compressor is to operate. The pressure be visible in the sight glass (or transparent tube). Sluggish flow at
must not exceed the maximum operation pressure which is full load indicates a need to clean the return line strainer or
stamped on the compressor serial number plate. The following scavenge orifice. When the little hole of the scavenge orifice is
explanation applies to a typical installation with a desired plugged by a undesired particules or any corrossion then the oil
operating range and this information will apply to a compressor level in the separator tank falls down quickly. During oil level is
with any other operating range excepting the stated pressures. decreasing, the reason may be the plugging in orifice. In this
Start the compressor with the shut off valve closed (or slightly case, remove the scavenge arrangement (strainer, orifice and
cracked open). Compressor will make a passing between loaded others) and clean it/them by compressed air or by a thin wire by
and unloaded positions. Provide reducing between this two taking care of not make any damage Figure 6.6. Simply check the
modes by slightly opening the shut off valve. Observe the line oil level from the sight glass (or transparent tube). DO NOT
pressure on the control panel display. When the line pressure widen the diameter of the scavenge orifice. This may reduce the
reaches the set pressure, the controller should unload the capacity of the compressor.
compressor. If the controller does not unload or it unloads the
compressors prior to the desired pressure, adjust the working
pressure setpoint by using working (load-unload) pressure
adjustment instructions/procedures on the controller’s manual
which is given separately in addition to this manual.
NOTE: If your compressor has EKOMASTER II or
EKOMASTER V or another electronic control system/panel,
please read the electronic control panel (&display) manual
(EKOMASTER II, EKOMASTER V, S1, S1-10, R1, P1, M6, L1
controller software specification or another one) which is given
separately, in addition to this manual.
FOR PRESSURE RANGE ADJUSTMENT
1. See two adjusting screw on the pressure switch to set high
and differential values of the operation pressure ranges of the
compressor. Figure 6.5: SCAVENGE LINE PIPE
2. The screw on the right hand side-when looking from the
front side of the pressure switch- is the high pressure setting
screw. Turn the screws softly during adjustment.
3. If the compressor start to run in unload mode before required
pressure, turn screw counterclockwise slightly up to reach
desired pressure.

FOR DIFFERENTIAL ADJUSTMENT

Differential setting is being done to run compressor in load
position on desired pressure. Differential is the difference
between the high and low pressure settings. After the setting of
the high pressure of the compressor, turn the differential
adjusting screw to complete the setting. Differential setting screw
is located on the left hand side of the pressure switch. If the
compressor runs on load before desired pressure then differential
setting must be adjusted. Turning the screw clockwise widens the
differential. In order to reduce the setting is done correctly, fully
open the shut off valve and allow the compressor to fill in the
service line. Simply check that the compressor is running in
unload and load positions at adjusted rates.

DANGER
DO NOT touch the electrical contacts, terminal or leads with
any metallic object. Severe electrical shock may occur.DO
NOT let the pressure switch cover open.

Figure 6.6: SCAVENGE ARRANGEMENT

Figure 6.4: PRESSURE SWITCH (Electromechanic control)

12
 6.MAINTENANCE

G - MOISTURE SEPARATOR MAINTENANCE

As optional usage, there is a moisture separator outside of the
compressor service air line in order to remove the water which is
condensed in oil/air cooler. This moisture separator (Figure 6.7)
drains the condensate which is collected in the vessel,
automatically by a timer.
DANGER !
Stop the air intake and release all internal pressure before
any maintenance or repairs.

In order to service, open the moisture separator vessel by

removing fixing bolts between the housing and the cap. Clean
the vessel and the internal parts before reassembling. Check
the drain valve, clean or replace if it is neccessary. Use a new
o-ring, lubricate it with grease, then reassemble the moisture
separator vessel, drain valve and drain line.
CAUTION !
Assemble the vessel by tighening with the torque of 4.5-36
Nm (40-320 in-Ibs).
Figure 6.7: MOISTURE SEPARATOR (Optional)

DRAIN TIMER ADJUSTMENT:

The factory setting for condensate drain timer is 1 minute
(running interval) and 3 seconds (open/discharge duration).
Generally, it can be adjusted between 1 to 5 minutes (running
interval) and 3 to 6 seconds (open duration). Please adjust drain
timer depending on condensate quantity. The drain/solenoid
valve must be open till discharging all of the collected
condensate in the vessel; not less, not more…

13
 6.MAINTENANCE

6.8.A. SERVICE INSTRUCTIONS FOR THREE- PHASE MOTORS

1. The electric motor has left our ex-works as assembled on air
compressor, completed electic connection and dynamically
balanced, which is ready for operation.
For trouble-free, functioning care should be taken to ensure
that the motors are not exposed any harmful effects during
transportation and in the event of any such damage, please
inform.
2. When the motor has not been used for a prolonged period of
time, the following work must be performed before start up
-Inspect the bearings and renew the grease, if necessary.
-If the insulation resistance is less than 2 MΩ at a winding
temperature at 25 ºC, when measured at 500V. Dry the
winding by using hot air with a max. temperature of 80 ºC.
3. The rotor of the motor is dynamically balanced with a fully
featherkey inserted in the shaft end. Driven members (Pulley,
coupling half) must be balanced on a plain spigot. The
sensitive antifriction bearings require the couplings, belt
pulleys and the like be pressed on with the aid as suitable
devices. Should this be impossible, the parts have to be
heated to about 60 to 80 ºC in order to allow them to be
pushed on to the shaft easily.
6. Check data on the rating plate. The voltage marked on the
rating plate must be in agreement with the main voltages.
7. In all of our compressors, electric motors have WYE-
DELTA starter (except some special requests). So, the
therminal board is normally equipped with 6 terminals
8. Specifications VDE 0580 and VDE 0100 require that all
motors to be earthed properly. Please use the special terminal
in the terminal box for this purpose.
9. When operating the motor at rated voltage and rated output,
the motor temperature rise at a maximum ambient
temperature of 40 ºC must not exceed 80 ºC for class F
insulation.
10. To avoid the danger of overloading and operation on 2
phases, the motors should be protected either with fuses,
thermal, thermo-magnetic switches or electronic circuits.

4. You can prolong the service life of your motors by aligning

them carefully. This applies to motors both with flexible and
non-flexible couplings. Even slight misalignments may very
rapidly result in damage to the bearings.Please take care that
the four feet are evenly loaded.

5. Unless the type of grease has been specified in the purchase

order or to cope with special load conditions in the bearings,
we have lubricated the motor with a bearing grease based on
lithium, type K-L3K according to DIN’51825,viscosity No.3
in the case of motors without relubricating device, which are
designed for continuous operation under normal operating
conditions and for direct coupling to the machine to be
driven, the first filling is sufficient for 20.000 service hours
for motors with 4 and more poles. 10.000 service hours for 2-
pole motors. In the presence of severe operating conditions,
e.g., high humidity, a comparatively high degree of pollution,
high or changing load on bearings ambient temperature
above 40 ºC, the lubrication intervals should be shortened. It
is recommended to have the the bearings cleaned and
inspected by an expert every 2 to 5 years. If the motors are
exposed to a high degree of humidity and comparatively
heavy contamination, the bearings should be cleaned at
shorter intervals. For cleaning, commercial gasoline should
be used. Please see to it that the same kind of grease is used
for refilling or relubricating.

14
 6.MAINTENANCE

Figure 6.8: PIPING and INSTRUMENTATION DIAGRAM

15
 6.MAINTENANCE

6.9 INVERTER MAINTENANCE AND INSPECTION FOR ALL VST COMPRESSORS

Maintenance period: Within 18 months of shipping from the factory or within 12 months of being delivered to the final
user, whichever comes first.

Daily inspection:

Check the following items with the system in operation.

1. The motor should not be vibrating or making unusual noises.

2. There should be no abnormal heat generation.
3. The ambient temperature should not be too high.
4. The output current value shown on the monitor display should not be higher than normal.
5. The cooling fans on the inverter should be operating normally.

Periodic inspection:

Check the following items during periodic maintenance.

1. Always turn OFF the power supply before beginning the inspection.
2. Confirm that the LED indicators on the front cover have all turned OFF, and then wait the time mentioned on
the yellow label has elapsed before beginning the inspection. Be sure not to touch terminals right after the
power has been turned off. Doing so can result in electric shock.

Parts Checks Remedies

External terminals, Are all screws and bolts tight? Tigthen loose screws and bolts firmly.
mounting bolts/screws, Are connectors tight? Reconnect the loose connectors.
connectors
Cooling fins Are the cooling fins dirty or dusty? Clean off any dirt or dust with an air
gun using dry air, max. 6 bar.
PCB’s Is there any conductive dirt or oil mist on the the PCB’s? Clean off any dirt or dust with an air
gun using dry air, max. 6 bar.
Cooling fans Is there any abnormal noise or vibration? Or, has the total Replace the cooling fans.
operating time exceeded 20000 hours?
Power elements Is there any conductive dirt or oil mist on the the PCB’s? Clean off any dirt or dust with an air
gun using dry air, max. 6 bar.
DC Capacitors Are there any irregularities, such as discoloration or odor? Replace the DC capacitors of the
inverter.

Periodic maintenance of parts:

The inverter includes various parts and all of them must work properly in order to make full use of the inverter
functions.

Among the electric components, there are some that require maintenance depending on their usage conditions. In order
to keep the inverter operating normally over a period of time, it is necessary to perform periodical inspections an replace
parts according to their service life.

Periodic inspection standards vary depending the inverter’s installation environment and usage conditions. The
inverter’s maintenance periods are noted below. Keep them as reference

Part Replacement Interval Replacement Method

Cooling fans 2 to 3 years Replace with new parts.
DC capacitors 5 years Replace with new parts.
Fuse (charging resistor) - Check during maintenance.
Aluminium capacitor on PCB 5 years Replace with new board. Decide during inspection.

NOTE: Inverter maintenance is a subject of EKO VST, EKO DVST and EKO GDVST series screw air compressors, only. Inverters (Frequency
converters) are not used in other type EKO compressors .

16
 6.MAINTENANCE

6.10. MAINTENANCE RECORD

MODEL: SERIAL NO:

DATE HOURMETER MAINTENANCE PERFORMED WORK PERFORMED BY AUTHORIZED BY

17
 7.TROUBLESHOOTING

7.1 INTRODUCTION Doing so can prevent unneccessary damages always remember to :

The information contained in the troubleshooting chart is based
upon both the reports about actual field applications and extensive
testing done at the factory. It contains symptoms and usual causes
for the described problems. However DO NOT assume that these
are the only problems that may occur.
All available data concerning the trouble should be systematically
analysed before undertaking any repairs or component
replacement procedures. A detailed visual inspection is worth
performing for almost all problems.
1. Check for loose wiring.
2. Check for damage piping.
3. Check for parts damaged by heat or an electrical short circuit,
usually apparent by discoloration or a burnt odor.
Should your problem persist after making the recommended check,
consult your nearest Ekomak representative or the Ekomak's
factory.
WARNING!
Take care of the performing any repairs or maintenance or
troubleshooting process by trained and those who know what
to do persons or by our company

7.2 TROUBLESHOOTING
SYMPTOM
1 Compressor is not starting
Compressor runs difficultly
2 0°C.
or does not start to run
Compressor is not
3 producing air (does not
run on load)
POSSIBLE CAUSE
A Energy does not come the compressor.
B Line fuse blown.
Low incoming voltage or the position
C voltage or the phases are connected wrong. The
of 3 phases are connected wrong.
The compressor have stopped due to a
D
failure.
The earth and neutral connection is not
E Please connect neutral (Mp) and earth cables.
been made.
The diameter of the incoming cable is
A
not enough.
B Low incoming voltage.
C The ambient temperature is too low.
D Non-pressurised sump.
E The intake valve defective.
F Minimum pressure valve defective.
The pressure in the line of factory may
A be higher than the on load working
pressure level of the compressor.
B Inlet valve defective.
C Minimum pressure valve defective.
D Solenoid valve defective/plugged.
The setting rates of pressure switch
changed or pressure switch defective.
E1
(compressors with electro-mechanic
control)
The electronic panel or pressure sensor
E2 defective (compressors with electronic
control)
The compressor does not transit from
F
wye to delta.
REMEDY
Energise the compressor.
Check the fuse.
Motor protection relay cuts the energy. Please
check if the light on this relay. If the light is off that
means there is a problem with the incoming
incoming voltage should be minimum 360 V @ 3
phases (R,S,T). If the phases connected wrong,
change the position of 2 phases.
Check the failure lights on the control panel. If
your compressor is equipped with electronic
panel, please read to the electronic panel manual
to understand the meaning of the fault signal.
Please check if your cable size is enough
depending to the cable sizes table. If your cable
size is not enough, the incoming voltage can drop
lower than minimum limits.
Motor protection relay cuts the energy. Please
check if the light on this relay. The incoming
voltage should be minimum 360 V @ 3 phases
(R,S,T).
The ambient temperature should be higher than
Before running of the compressor be sure that
the sump is depressurized.
Please check if the inlet valve is working properly.
Please check if minimum pressure valve is
working properly. Start the compressor and check
the separator tank pressure. If the separator tank
pressure is not increasing that means the
minimum pressure valve is defective. Change the
necessary parts.
Wait until the pressure decrease to the on load
working pressure level of the compressor.
Please check if the inlet valve is working properly.
See 2F
Please check if the selenoid valve is working
properly.
Check the set rates. If during running mode, the
compressor is not going onload and the onload
light is off that means the pressure switch is
defective.
Please check if energy comes to the solenoid
valve (SV1) when the compressor transits onload
working mode. If energy does not come either
pressure sensor or electronic panel is defective.
A ) The ZR1 time relay can be defective or setted
wrongly. The set time should be 6 secs.
B ) If your compressor is equipped with electronic
panel, the panel could be defective.

18
 7.TROUBLESHOOTING
SYMPTOM POSSIBLE CAUSE REMEDY
Check air leakages. If there is air leakage you
A Air demand is too high or air leakage. should replace your compressor or add a new
compressor.
Compressor does not B Panel filter dirty. Check and replace if necessary.
4 reach to maximum C Inlet valve defective. Please check if the inlet valve is working properly.
pressure level
D Air filter dirty. Check and replace if necessary.
Disconnect the main power and take out the
E Mechanic failure in the air end unit. coupling guard. Check if you can rotate the
coupling easily. If not consult factory.
The setting rates of pressure switch
changed or pressure switch defective.
A1
(Compressors with electro-mechanic Check the set rates.
control)
Compressor does not The pressure settings can be changed
A2 Check the set rates.
5 go unload at the maximum on the electronic panel.
pressure level B Inlet valve defective. Please check if the inlet valve is working properly.
Please check if the selenoid valve is working
C Solenoid valve defective/plugged.
properly
Air leakage in the pneumatic line of the Check if there is an air leakage on the pneumatic
D
compressor. line of the compressor
The orifice or strainer on the scavenge Clean the scavenge live by compressed air. If
A
line plugged. necessary disconnect and clean it.
The scavenge pipe does not reach to
Too much oil carried-over B Check the size of the pipe. Replace if necessary.
6 the bottom of separator tank.
in delivery air
The separator filter defective or time to
C Check and replace if necessary.
change.
D Oil leakage in the compressor. Check the connections in the compressor.
Check the set value of the relay. Afterwards Reset
Set value of overload relay is wrong or
A the relay and run the compressor. Check if the
overload relay is defective.
currents are lower than the current limit
Please check if the light on this relay. The
B Low incoming voltage. incoming voltage should be minimum 360 V @ 3
phases (R,S,T).
Check the pressure differences between P1 and
Main motor overload relay C Separator filter is plugged.
7 P2. The difference should be lower than 1.5 bar.
(M1) stops compressor
The setting rates of pressure switch
changed or pressure switch defective.
D1
(Compressors with electro-mechanic Check the set rates.
control)
The pressure settings can be changed
D2 Check the set rates.
on the electronic panel.
E Mechanic failure in the air end unit. See 4E
Check the set value of the relay. Afterwards reset
Set value of overload relay is wrong or
A the relay and run the compressor. Check if the
overload relay is defective.
currents are lower than the current limit
Fan motor overload relay
8 Check the cooler, air filter and panel filter, replace
(M2) stops compressor B Ventilation problem.
if necessary.
Check if the currents are lower than the current
C Fan motor defective.
value on the nameplate of the fan motor.
Pressure switch (P2) defective / set
A Check the set rates.
value wrong.
Pressure switch (P1) defective / set
B Check the set rates.
Compressor stops due value wrong.
9 Check the pressure differences between P1 and
to high pressure fault C Separator filter is plugged.
P2. The difference should be lower than 1.5 bar.
D The outlet valve closed. Check and open it.
E Minimum pressure valve defective. Please check and replace if necessary.

19
 7.TROUBLESHOOTING

SYMPTOM POSSIBLE CAUSE REMEDY

Check if there is enough ventilation. The ambient
A Ambient temperature too high.
temperature should be lower than 45°C
B Oil level too low. Check and add oil if necessary.
C Oil filter plugged. Check and replace if necessary.
D Panel filter / air filter plugged. Check and replace if necessary.
High temperature fault E Thermostatic valve defective. Check and replace repair kit if necessary.
10
stops compressor. F Oil loses its viscosity / oil level too low. Replace/add oil.
G Cooler is plugged. Check and clean the cooler.
H Mechanic failure in the air end unit. See 4E.
The thermometer or temperature sensor
I Check and replace if necessary.
is defective.
J Fan motor defective. Check and replace if necessary.
The setting rates of pressure switch
changed or pressure switch defective.
A1
(Compressors with electro-mechanic Check the set rates.
control)
The pressure settings can be changed
A2 Check the set rates.
on the electronic panel.
11 Safety valve opens Check the pressure differences between P1 and
B Separator filter is plugged.
P2. The difference should be lower than 1.5 bar.
Please check if the selenoid valve is working
C Selenoid valve defective/plugged.
properly.
D Inlet valve defective. Please check if the inlet valve is working properly.
E Safety valve set value defective. Check and replace or reset if necessary.
Please check and tighten the connections
A Loose connection in the compressor.
carefully.
Compressor is
12 Mechanical problem in the motor
working very noisy B Please check and replace if necessary.
bearings.
C Mechanic failure in the air end unit. See 4E.
Please check and change working mode if
Compressor does not A Wrong operation mode selected.
13 necessary.
stop in auto mode
B Timer (ZR2) defective / set value wrong. Adjust or change if necessary.
A Defective control buttons. Change the buttons.
14 Compressor does not stop
B Defective contactor. Please check and replace if necessary.

20
 COOLING AIR EXHAUST DUCTS

HOT AIR OUTLET FROM TOP (COOLER AT TOP)

A B

HOT AIR OUTLET FROM SĐDE (COOLER AT SIDE)

A
B

21
Table 1

CABLE SIZES, CIRCUIT BREAKER SETTINGS

MODEL (D, GD) KW / HP CABLE SIZE CIRCUIT BEAKER

2
EKO 15 15 / 20 3 x 6 mm + N + E 40 A
2
EKO 18 18 / 25 3 x 10 mm + N + E 40 A
2
EKO 22 22 / 30 3 x 10 mm + N + E 50 A
2
EKO 30 30 / 40 3 x 16 mm + N + E 63 A
2
EKO 37 37 / 50 3 x 25 mm + N + E 80 A
2
EKO 45 45 / 60 3 x 25 mm + N + E 100 A
2
EKO 55 55 / 75 3 x 35 mm + N + E 125 A
2
EKO 75 75 / 100 3 x 50 mm + N + E 160 A
2
EKO 90 90 / 125 3 x 70 mm + N + E 200 A
2
EKO 110 110 / 150 3 x 95 mm + N + E 250 A
2
EKO 132 132 / 180 3 x 120 mm + N + E 250 A
2
EKO 160 160 / 220 3 x 120 mm + N + E 300 A
2
EKO 200 200 / 270 3 x 150 mm + N + E 400 A
2
EKO 250 250 / 340 3 x 150 mm + N + E 500 A

Maximum Cable length : 50 m (If it is more than 50 m, use one bigger cable size)
N : Neutral
E : Earth

22
 Table 2

MOTOR BEARINGS LUBRICATION SCHEDULE

MOTOR LUBRICATION GREASE GREASE GREASE

POWER
SPEED PERIOD MOUNT CHANGE TIME ADDITION GREASE TYPE
(kW)
(rpm) (hour) (gr) (hour) (gr)

75 1500 2000 25 16000 145 SKF LGWA 2

90 1500 2000 25 16000 145 SKF LGWA 2
75 3000 2000 25 16000 145 SKF LGWA 2
90 3000 2000 25 16000 145 SKF LGWA 2
110 1500 2000 40 16000 260 SKF LGWA 2
132 1500 2000 40 16000 260 SKF LGWA 2
160 1500 2000 40 16000 260 SKF LGWA 2
110 3000 2000 30 16000 170 SKF LGWA 2
132 3000 2000 30 16000 170 SKF LGWA 2
160 3000 2000 30 16000 170 SKF LGWA 2
200 1500 2000 50 16000 325 SKF LGWA 2
250 1500 2000 50 16000 325 SKF LGWA 2
200 3000 2000 35 16000 210 SKF LGWA 2
250 3000 2000 35 16000 210 SKF LGWA 2

Grease as the amount given on the table, must be added to the bearing balls and to the bearing back cover after
replacing the bearings and cleaning the bearing covers throughly. Bearing front cover should be empty unconditionally.

SKF LGWA 2 type grease should be used. In addition to, equivalent types are indicated below.
Gres other than these types must not be used.

SHELL ALVANIA R3
ESSO UNIREX N3

Lubrication details are given on the lubricating label on the machine.

NOTE: Bearing lubrication should be performed while the motor is running.

23
 Table 3

RECOMMENDED SPARE PARTS AND SERVICE OPERATIONS

EKOMAK COMPRESSORS - EKO D, GD SERIES

12000 or 18 months

20000 or 30 months

28000 or 42 months
250 our 500 hours

4000 or 6 months

16000 or 2 years

24000 or 3 years

32000 or 4 years
8000 or 1 year

110000
10000

13000
14000
15000

17000
18000
19000

21000
22000
23000

25000
26000
27000

29000
30000
31000
Recommended spare parts and

1000
2000
3000

5000
6000
7000

9000
service operations

Oil - (AIRMAX 46) X X X X

Oil - (AIRMAX 2000) * X X X X X X X X X X X X X X X X
Air filter element X X X X X X X X X X X X X X X X
Oil filter element X X X X X X X X X X X X X X X X
Panel filter X X X X X X X X X X X X X X X X
Separator element X X X X X X X X
Hydraulic hoses X X
Pneumatic hoses X X
Kit, inlet valve Type 1 (VMC RH10) X X X X
Kit, inlet valve Type 1 (VMC RH38) X X X X
Kit, inlet valve Type 2 (MER 122) X X X X
Kit, inlet valve Type 3 (C150) X X X X X X
Kit, inlet valve Type 4 (HDKG 85-120) X X X X
Kit, inlet valve Type 5 (VMC RH350-RH600) X X X X X X
Solenoid valve X X
Kit, contactor X X
Kit, minimum pressure valve X X X X
Kit, scavenge X X
Thermostatic valve element X X X X
O-ring, oil filling plug X X X X X X X X X X X X X X X X
Coupling X X X
Motor bearings X X
Fan motor bearings X
Air end revision X
Pressure sensor X X
Temperature sensor X X
Temperature gauge X
Regulation pressostat X X
Safety pressostat X

SERVICE OPERATIONS
Check oil level EVERY START-UP
Check / Clean air filter element Every 1000 hours
Check load / unload working modes Every 1000 hours
Check air and oil leakages Every 1000 hours
Check scavenge line Every 1000 hours
Clean separator moısture Every 2000 hours
Clean strainer Every 2000 hours
Check screws for electrical connections Every 2000 hours
Clean cooler Every 4000 hours
Check screws for connections Every 4000 hours
Air end seal leakage checking Every 8000 hours
Bearing grease ACCORDING TO INTRUCTION ON MOTOR PLATE. Refer Table 2

ADVISED SPARE STOCK

Solenoid valve Replacement times have been calculated according to
Temperature gauge normal running conditions which informed by technical
Temperature sensor specifications.
Pressure sensor
Regulation pressostat First section shows the changing period of components.
Kit, inlet valve Second section shows the checking period.
Kit, contactor
(*) Equivalent lubricants:
Kit, minimum pressure valve ISO VG46 grade oils for rotary screw air compressors.
Kit, scavenge
Coupling

Compressor Life Time: Compressor life is declared 10 years according to Industrial Goods’s Aftersales Service Legislation.
“Ekomak undertakes providing spare parts of compressors for 10 years from the sales date.”

24
 PROCEDURE FOR ORDERING PARTS

Parts should be ordered from the nearest Ekomak representative or the representative from whom the compressor was purchased.
If for any reason parts cannot be obtained in this manner, contact the factory directly at the adress, fax or phone numbers below.

When ordering parts always indicate THE SERIAL NUMBER of the compressor. This can be obtained from the Bill of lading for the
compressor or from the Serial number plate located on the compressor.
The genuine Ekomak service parts listed meet or exceed the demands of this compressor. Use of replacement parts other than those
approved by Ekomak may lead to hazardous conditions over which Ekomak has no control. Such conditions include, but are not limited
to,bodily injury and compressor failure.

PLEASE READ THE PART LIST BOOK FOR ILLUSTRATIONS AND SPARE PART LIST OF YOUR EKO COMPRESSOR.

EKOMAK A.S.
ATATURK CADDESI MECLIS MAHALLESI OKUL SOKAK NO:5 SARIGAZI
81260
ISTANBUL/TURKIYE
phone: 00 90 216 540 11 33 (PBX)
fax: 00 90 216 415 41 39
web site : www.ekomak.com.tr

EKOMAK AUTHORIZED SERVICES AND DEALERS

Service Name Service Address Service Phone Service Fax
Belblitz 12-201, Filatowa Str. +375-17 295 6705
220026 Minsk Republic of +375-17 295 6706
Belarus +375-17 285 5364
+375-17 296 2021
Airmatic No 21, Jalan Tambur 603-5124 2669 603-5122 3669
Machinery Sdn 33/19, Section 33, Shah 603-5124 7200
Bhd Alam Technology Park 603-5124 7223
40400 Shah Alam, 603-5124 7232
Selangor Darul Ehsan,
Malaysia
Ekomak Moskow OOO “EKOMAK” +7495 585 07 45 +7495 981 88 29
Olimpiyskiy Prospekt, D.46,
Korpus 3 g.Mytishi,
Moskovskiy Region
141006, Russia

Ekomak GmbH Eurotec-Ring 15 D-47445 +49 2841 16954 25 +49 2841 16954 30
Moers Germany
IMO Industrial P.O. Box: 20376 06-5437991 06-5437994
Machines Trd. Co. Sharjah – U.A.E 06-5437992

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