Atlas Copco Elektronikon MK5 Controller Operation Guide

Atlas Copco Elektronikon MK5 Controller: A Complete Guide from Beginner to On site Operations

In a compressed air system, the controller is both the "brain" of the equipment and the core interactive interface between the operation and maintenance personnel and the unit. The Elektronikon MK5 controller (also known as the Swipe controller) launched by Atlas Copco greatly simplifies the daily management and fault diagnosis of compressors with its intuitive touch and slide operation, multi-level user permissions, and rich monitoring functions. However, many on-site engineers often spend extra time when faced with first-time startup, parameter adjustment, or alarm reset due to unfamiliarity with menu hierarchy. This article is based on the official operation manual of Elektronikon MK5, systematically sorting out its hardware layout, menu structure, key parameter settings, and maintenance points, providing a practical operation guide for compressor operation and maintenance personnel.

Controller Overview and Hardware Functions

Elektronikon MK5 is an intelligent controller designed specifically for industrial compressor units, integrating three core functions: control, protection, and monitoring.

Control function: By preset loading/unloading pressure values, the pipeline pressure is automatically maintained within the set range, while taking into account limiting conditions such as minimum downtime and motor start-up times, achieving energy-saving operation. The controller supports three control modes: local, remote, and LAN, and has time driven automatic start stop programming capability.

Protection function: Real time monitoring of key parameters such as compressor exhaust temperature, motor overload, fan overload, etc. Once the safety threshold is exceeded, immediately shut down and display fault information. In addition, a shutdown warning level is provided to alert operators in advance before reaching the shutdown value, reminding them to intervene in a timely manner.

Monitoring and maintenance: Built in service timer that automatically prompts when the maintenance cycle is reached; Simultaneously record data such as running time and start stop frequency to facilitate the development of preventive maintenance plans.

On the hardware level, the MK5 is equipped with a high-resolution touch screen display with vertical sliders on both sides for menu scrolling and numerical adjustment, and a horizontal slider at the bottom for page switching. The panel integrates start/stop buttons, home button, and status indicator lights (running, alarm, service, voltage indication). The operator does not need an external keyboard and mouse, and all operations are completed through touch and sliding, adapting to the glove wearing scene in industrial sites.

User permission system and secure access

The MK5 controller adopts three-level user permission management to protect key parameters from being mistakenly modified:

Basic User: Only able to view partial data, unable to modify any settings, suitable for ordinary operators.

Advanced User: can access and modify most operating parameters (such as loading pressure, unloading pressure, control mode, etc.), suitable for process engineers or team leaders.

Service User: has the highest authority, can enter the "Service" menu to reset the service timer, and can activate advanced features such as automatic restart (ARAVF). This level is protected by a 4-digit password and must be obtained by the supplier or authorized personnel.

To switch user levels, you need to enter the "Access Level" sub item under the Controller Settings menu. If Service User is selected, the system will pop up a password input interface, and the operator can select numbers one by one through the vertical slider on the right side. After confirmation, it will take effect. Correctly setting permission levels is the first line of defense to ensure the safe operation of devices.

Main interface and navigation logic

3.1 Main Screen

After power on, the controller automatically displays the main screen. The top is an information bar that displays the current status of the unit (such as running, loading, unloading, etc.); The middle area displays the main process values (such as exhaust pressure or temperature) and is equipped with analog bar indicators; At the bottom is the page indicator point (breadcrumb), indicating the current level.

Users can scroll up and down through the left vertical slider to switch between the main menu items (Machine Settings, Aux. Equipment, Data, Service, Controller Settings, Information). Swipe left and right with the horizontal slider to enter the various sub pages of the current menu. The "Home" button in the upper right corner allows you to return to the home screen with just one click, regardless of which level you are at.

3.2 Status Icons and System Icons

The screen will dynamically display various status icons, such as:

Operating states such as motor stop, waiting, loading, unloading, manual unloading, etc.

Control mode: Local, Remote, or LAN control.

Automatic restart (ARAVF) activation indicator.

The system icon identifies the current user level (basic/advanced/service) and the reset operation entrance. Understanding the meanings of these icons can help quickly determine the operating conditions of the equipment.

Detailed explanation of core menu functions

4.1 Machine Settings Menu

This menu is the most frequently operated area and includes the following subpages:

Setpoint 1 and Setpoint 2 (optional): Used to set the loading pressure (Load) and unloading pressure (Unload). There are usually two sets of settings that can be switched according to gas demand. Select the value when modifying, then adjust it up and down using the vertical slider on the right, confirm and save.

Regulation: The PID control coefficient and pressure band width can be adjusted to affect the response speed of the unit to pressure fluctuations. Generally, the factory default is maintained and only optimized by professionals when special process requirements are met.

Control Mode: Provides three modes: local (panel button start stop), remote (external digital input), and LAN (Ethernet command). After switching, the start stop button on the panel will be activated or deactivated accordingly.

Auto Restart: ARAVF function - when the power failure is restored, if the controller is in automatic operation mode at that time, the unit will automatically restart. This feature is disabled by default at the factory and needs to be activated by entering a password as a Service user. After activation, ARAVF warning labels should be affixed near the unit.

4.2 Auxiliary Equipment Parameters Menu

This menu is only visible to Advanced and above users and is used to configure accessory parameters such as dryer, fan, phase sequence detection, and SmartBox (wireless module). For example:

Dryer: Set the operating mode of the dryer, dew point temperature warning value, etc.

Fan: Configure the start and stop temperature points for the cooling fan.

SmartBox: Used to connect to Atlas Copco's wireless monitoring system and view antenna received signal strength.

4.3 Data Menu

This menu provides read-only information, including three main sub pages:

Counters: Display cumulative values such as total operating hours, loading hours, and motor start-up times, which are the basis for evaluating equipment wear and developing maintenance plans.

Input: List the status of all digital and analog inputs (such as pressure sensor values, temperature sensor values, remote start stop signals, etc.) for easy troubleshooting of external signal faults.

Output: Display the output status of each relay (such as loading valve, unloading valve, alarm output, etc.), used to verify whether the control logic is operating normally. The manual specifically reminds that these voltage free output contacts can only be used for functional control and must not be connected to safety circuits.

4.4 Service Menu

This menu is only visible to Service Users and includes:

Next Service: Display the remaining operating hours until the next maintenance. When the accumulated running time exceeds the set service interval, the service indicator light on the panel will light up.

Reset: After completing the maintenance work, reset the service timer to zero and restart the next cycle. When operating, follow the on-screen prompts to confirm and avoid accidental reset.

Safety Valve Test: Used to record the date of regular testing of safety valves (information only, not automatically executed).

4.5 Controller Settings Menu

Includes general system settings:

Access Level: Switch user levels as described earlier.

Language: Supports switching between multiple languages, and the controller will automatically restart after the change.

Units: Can switch between metric/imperial units (such as bar/psi, ℃/℉).

CAN Settings: Configure CAN bus parameters (if used for multi unit control).

Ethernet Settings: Set the IP address, subnet mask, and gateway for accessing the factory LAN or upper level monitoring system.

Display Timeout: Set the delay for the screen to automatically turn off after no operation, in order to extend the lifespan of the display screen and save energy.

4.6 Information Menu

Provide identification information such as controller firmware version, MAC address, and application software description to facilitate quick provision of device "ID" during after-sales support.

Alarm handling and fault reset

When an abnormality occurs in the unit, the controller will trigger a warning or shutdown. Warning is usually a warning (such as high temperature, high dew point), the machine may continue to operate, but the alarm indicator light will flash. Stop the equipment immediately and lock the start until the fault is resolved and manually reset.

Reset operation process:

Swipe left on the main screen to the Status page. If there is an active alarm, the vertical slider on the right will display the "Reset" icon.

Click on the slider on the right, and a confirmation dialog box will appear on the screen, displaying the reset icon (green check) and cancel icon (red cross).

Click the confirm button and the system attempts to reset. If the fault condition has been eliminated and the alarm disappears, the equipment can be restarted; If the condition is not eliminated and the reset is invalid, the fundamental problem needs to be addressed first.

Manual strongly warns: Do not repeatedly reset the alarm without solving the root cause, otherwise it may cause serious damage to the equipment. For example, if the exhaust temperature is too high and causes a shutdown, the cooling system, environmental ventilation, or temperature control valve should be checked first, and then reset after the temperature drops to normal.

Enabling and Risks of Automatic Restart (ARAVF) Function

ARAVF is highly valuable in unmanned or remote stations, but it must be used with caution. Its activation requires Service permission and password. Specific steps:

Go to the Machine Settings → Auto Restart page.

Change the option from 'Disabled' to 'Enabled', and the system prompts for a password.

The function takes effect after entering the correct password.

After activation, if the controller shuts down due to power interruption, when the voltage is restored and the controller is in "automatic" mode, the unit will start automatically without manual intervention. This means that maintenance personnel must manually switch the controller to the "local" or "stop" state during maintenance, otherwise accidental power transmission may cause the compressor to suddenly start, resulting in personal injury. Therefore, the manual explicitly requires that an ARAVF warning sign must be affixed near the controller after activation.

Daily operation skills and maintenance suggestions

Parameter modification confirmation: After any numerical modification, be sure to click the "V" on the horizontal slider to confirm, otherwise the modification will be invalid. If you want to give up, click "X" to cancel.

Screen cleaning: After turning off the power, use a soft dry cloth to wipe and avoid using organic solvents.

Regularly check the input/output status: Observe whether the sensor readings are reasonable through the Data menu, such as whether the pressure transmitter is drifting or the temperature probe is open circuit.

Service timer management: It is recommended to set reasonable intervals according to the manufacturer's maintenance schedule (such as replacing oil filters, air filters, and oil separation cores), and reset the timer after each maintenance to ensure accurate reminders.

Firmware upgrade: It can be done through Ethernet or USB, but it needs to be operated by an authorized service provider to prevent version incompatibility.

Common problem troubleshooting quick search

Possible causes and measures for handling the phenomenon

The screen shows no display, the power supply is not connected or the fuse is blown. Check the main power supply and control transformer fuse

Press the start button to switch from remote or LAN control mode to local mode or check remote signal without any response

Frequent loading/unloading of pressure bands with narrow settings or large gas fluctuations, appropriately relaxing the pressure band values or checking for leaks in the pipeline network

The service light is on, reaching the maintenance time. Perform maintenance and reset the timer

Alarm cannot reset. Actual parameters still exceed the measured actual temperature/pressure. Reset after troubleshooting

Ethernet communication failure, IP setting error or network cable failure. Check IP/subnet/gateway and test physical connection