MK4 To MK5 Upgradation Instructions

Upgrade Instruction
1. General information
Mk5 Upgrade Instruction
Printed Matter Number : 9845 0284 00 ed02

Applicable to : OIS compressors with MkIV Elektronikon : GA >= 90 , G , GR
Preliminary Operations :
Safety Instructions : General
Persons Required : 1
Special Tools :
Consumables :
2. Document overview
This document describes the following:
1. General information ............................................................................................................ 1
2. Document overview ............................................................................................................ 1
3. Safety first .............................................................................................................................. 3
4 . Introduction ....................................................................................................................... 4
CONFIDENTIAL: This document is property of Atlas Copco Oil Free Air and shall not without our permission be altered,
5. General................................................................................................................................ 4
6. Safety precautions .............................................................................................................. 6
6.1. Installation .................................................................................................................... 6
6.2. Operation ...................................................................................................................... 7
6.3. Maintenance ................................................................................................................. 7
7. Upgrade kits and content .................................................................................................... 9
Parts list 2230 5018 26 – MkIV to Mk5 ........................................................................ 9
copied, used for manufacturing or communicated to any other person or company.
7.1.
7.2. Parts list 2230 5018 27 – Optional kit ........................................................................ 10
8. Mechanical changes ......................................................................................................... 11
8.1. Cubicle door ............................................................................................................... 11
8.2. Expansion module(s) IO2 ......................................................................................... 11
8.3. Expansion module IO34 ............................................................................................ 11
8.4. Expansion module SPM . ( OPTIONAL ORDERING ) .............................................. 11
9. Electrical changes ............................................................................................................. 11
9.1. Wiring tool Mk5 Wago connectors ............................................................................. 12
9.1.1. Plier tool Grey WAGO connector .......................................................................... 12
9.1.2. Tool Black WAGO connector ................................................................................ 12
9.2. Service diagrams ....................................................................................................... 12
9.3. Rewiring ..................................................................................................................... 12
9.3.1. Wiring tables .......................................................................................................... 13
Document no.: 9845028400-01 Issue date: 5/22/2017 4:35:12 PM

Rev: 2 Page 1 of 27
9.4. Download instruction .................................................................................................. 15
9.4.1. Selection of data files for MkIV to Mk5 upgrades ................................................. 17
10. Powerless test instruction ............................................................................................. 22
10.1. First step ..................................................................................................................... 22
10.2. Adapted connections ................................................................................................. 22
10.3. Double-check ............................................................................................................. 22
11. Powered test instruction ................................................................................................ 23
11.1. First step ..................................................................................................................... 23
11.2. Sensor + input test ..................................................................................................... 23
11.3. Start with the power lines connected ......................................................................... 23
12. Clean up documentation ............................................................................................... 24
12.1. Wire harnesses .......................................................................................................... 24
12.2. Service diagrams and instructions ............................................................................. 24
13. Installation of SMARTBOX ............................................................................................ 25

Rev: 2 Page 2 of 27
Rev: 2
3. Safety first
Document no.: 9845028400-01

Issue date: 5/22/2017 4:35:12 PM
Page 3 of 27
4. Introduction
This instruction book describes how to handle the machines to ensure safe operation,
optimum efficiency and long service life.
Read this book before changing the machine to ensure correct handling, operation and
proper maintenance from the beginning. The maintenance schedule comprises measures for
keeping the machine in good condition.
Keep this book available for the trained personnel from Atlas Copco and make sure that the
machine is operated. Record all operating data, maintenance performed, etc. in an operator's
logbook available from Atlas Copco. Follow all relevant safety precautions, including those
mentioned in this book.
Trained personnel from Atlas Copco who can be contacted for any further information must
carry out repairs.
In all correspondence always mention the type and the serial number, shown on the data
plate and the number of this instruction.
The company reserves the right to make changes without prior notice.
This instruction book meets the requirements for instructions specified by the machinery
directive 2006/42/EC and is valid for CE as well non-EC labelled machines.
5. General
Kits are put together to convert a compressor with MkIV Elektronikon control to an Mk5
Elektronikon ( with Mk5 Graphic + module) controlled compressor. The kits contain the basic
components to do the conversion .
Check what type of motor coupling has been installed ! ( see ECB APF1691/C1).
Only for GA 132VSD and GA 160 VSD .
From APF152161 , Bowex coupling has been installed which can run at lower speed
900rpm to 600rpm .MkIV Datafile installed = gen2 :
 Download Mk5 models GA 132VSD & GA160VSD gen2 or gen4 ( see 8.4.1)
Serial numbers <APF152161 and S996321,S997103,S997679,S998374 have Spider

couplings installed and can’t run below 900rpm . MkIVdatafile installed = gen1:

Rev: 2 Page 4 of 27
To prevent damage on Spider couplings :
 Download Mk5 models GA 132VSD & GA160VSD gen0 and gen1 ( see 8.4.1)
For GA modular units ( model 2008 ) GA90-160+ & GA 110-160VSD (incl ER) ,
replace electronic bypass valves Y151 & Y152 (ER only) by thermostatic valves before
executing the upgrade ( see ECB APFF1828/C1 and ESB APFF 1851 ) !
All kits will include the SMARTBOX kit :

- see chapter 13 to install the SMARTBOX ( = PM 2946 1650 xx)

- for a detailed SMARTBOX installation instruction , refer to the PM 2946 1651 xx in the
GBP
- for the SMARTBOX installation video , refer to the CTS video website
Before starting the upgrade, read this instruction attentively. Compare the original configuration and settings
with the Mk5 version and write down the differences. Extra adaptations in software could be needed .
Before starting the upgrade write down:

- all active counters (e.g. running hours, loaded hours, motor start , load relay dryers starts, fan starts , …
- service intervals (running hours and real time hour)

Rev: 2 Page 5 of 27
6. Safety precautions
To be read attentively and acted accordingly before installing, operating or repairing
the unit.
These recommendations apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the application
which are not included herein.
In addition to normal safety rules which should be observed with stationary air compressors
and equipment, the following safety directions and precautions are of special importance.
When operating this unit, the operator must employ safe working practices and observe all
related local work safety requirements and ordinances.
The owner is responsible for maintaining the unit in a safe operating condition. Parts and
accessories shall be replaced if unsuitable for safe operation.
Installation, operation, maintenance and repair shall only be performed by authorized,
trained, competent personnel.
Any modification on the compressor or air dryer shall only be performed in agreement with
Atlas Copco and under supervision of authorized, competent personnel.
If any statement in this book, especially with regard to safety, does not comply with local
legislation, the stricter of the two shall apply.
These precautions are general and cover several machine types and equipment; hence
some statements may not apply to the unit(s) described in this book.
6.1. Installation
Apart from general engineering practice in conformity with the local safety regulations, the
following directives are specially stressed:
A compressor or air dryer shall be lifted only with adequate equipment in conformity with local safety rules.
Loose or pivoting parts shall be securely fastened before lifting. It is strictly forbidden to dwell or stay in the risk
zone under a lifted load. Lifting acceleration and retardation shall be kept within safe limits.
Wear a safety helmet when working in the area of overhead or lifting equipment.
Any blanking flanges, plugs, caps and desiccant bags shall be removed before connecting up the pipes.
Distribution pipes and connections shall be of correct size and suitable for the working pressure
Place the unit where the ambient air is as cool and clean as possible. If necessary, install a suction duct. Never
obstruct the air inlet. Care shall be taken to minimize the entry of moisture with the inlet air
The aspirated air shall be free from flammable fumes or vapours, e.g. paint solvents, which can lead to internal
fire or explosion
Air-cooled units shall be installed in such a way that an adequate flow of cooling air is available and that the
exhausted air does not circulate back to the inlet.
Arrange the air intake so that loose clothing of people cannot be sucked in.
Ensure that the discharge pipe from the compressor to the after cooler, air dryer or air net is free to expand under
heat and that it is not in contact with or close to flammable material.
No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
If remote control is installed, the unit shall bear an obvious sign reading:
DANGER: This machine is remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and that the isolating switch
is open and locked before starting any maintenance or repair.
As a further safeguard, persons switching on remotely controlled units shall take
adequate precautions to ensure that there is no one checking or working on the machine.
To this end, a suitable notice shall be affixed to the start equipment.
On units with automatic start-stop system, a sign stating "This machine may start without warning" shall be
attached near the instrument panel.
In multiple compressor systems manual valves shall be installed to isolate each compressor. Non-return valves
(check valves) shall not be relied upon for isolating pressure systems.

Rev: 2 Page 6 of 27
Never remove or tamper with the safety devices, guards or insulations fitted on the unit. Every pressure vessel or
auxiliary installed outside the unit to contain air above atmospheric pressure shall be protected by a pressure-
relieving device or devices as required.
For water-cooled machines with water shut-off valves installed at compressor cooling water in- and outlet, the
cooling water system has to be protected by a safety device with set pressure according to the maximum cooling
water inlet pressure and physical location as mentioned in this book.
Pipe work or other parts with a temperature in excess of 80 degrees Celsius and which may be accidentally
touched by personnel in normal operation shall be guarded or insulated. Other high-temperature pipe work shall
be clearly marked.
If the ground is not level or can be subject to variable inclination, consult Atlas Copco.
The electrical connections shall correspond to the local codes. The units shall be grounded and protected against
short circuits by fuses. An isolating switch must be installed near the machine, preferably a lockable type.
6.2. Operation
 Air hoses shall be of correct size and suitable for the working pressure. Never use frayed, damaged or
deteriorated hoses. Use only the correct type and size of hose end fittings and connections. When blowing
through a hose or air line, ensure that the open end is held securely. A free end will whip and may cause
injury. Make sure that a hose is fully depressurized before disconnecting it.
Never play with compressed air. Do not apply it to your skin or direct an air stream at people. Never use it
to clean dirt from your clothes. When using it to clean equipment, do so with extreme caution and use eye
protection.
The compressor is not considered as capable of producing air of breathing quality. For breathing air quality, the
compressed air must be adequately purified according to local legislation and standards.
Never operate the units when there is a possibility of taking in flammable or toxic fumes.
Never operate the units at pressures below or in excess of their limit ratings as indicated on the Principal Data
sheet.
Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to carry out
checks. Wear ear protectors when opening a door.

People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB (A) shall
wear ear protectors.
Periodically check that:
a. All guards are in place and securely fastened
b. All hoses and/or pipes inside the unit are in good condition, secure and not rubbing
c. There are no leaks
d. All fasteners are tight
e. All electrical leads are secure and in good order

f. Safety valves and other pressure-relief devices are not obstructed by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good repair, free of
wear or abuse
If warm cooling air from compressors is used in air heating systems, e.g. to warm up a workroom, take
precautions against air pollution and possible contamination of the breathing air.
Do not remove any of, or tamper with, the sound-damping material.
For water-cooled machines with water shut-off valves installed at compressor cooling water in- and outlet, the
operator must ensure that the cooling water system cannot be blocked when operating the unit.
6.3. Maintenance
Maintenance and repair work shall only be carried out under supervision of someone
qualified for the job.
 Use only the correct tools for maintenance and repair work.

Rev: 2 Page 7 of 27
 Use only genuine spare parts.
 All maintenance work, other than routine attention, shall only be undertaken when the unit is stopped, the
main power supply is switched off and the machine has cooled down. Take positive precaution to ensure
that the unit cannot be started inadvertently.
In addition, a warning sign bearing a legend such as "work in progress; do not start" shall be attached to
the starting equipment.
 Close the compressor air outlet valve before connecting or disconnecting a pipe.
 Before removing any pressurized component, effectively isolate the unit from all sources of pressure and
relieve the entire system of pressure.
 Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapours of cleaning liquids.
 Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts and
exposed openings with a clean cloth, paper or tape.
Never weld or perform any operation involving heat near the oil system. Oil tanks must
be completely purged, e.g. by steam-cleaning, before carrying out such operations.
Never weld on, or in any way modify, pressure vessels.
If performing any operation involving heat, flames or sparks on a machine, the

surrounding components shall first be screened with non-flammable material.
Whenever there is an indication or any suspicion that an internal part of a machine is
overheated, the machine shall be stopped but no inspection covers shall be opened
before sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of
the oil vapour when air is admitted.
Never use a light source with open flame for inspecting the interior of a machine,
pressure vessel, etc.
Make sure that no tools, loose parts or rags are left in or on the unit.
All regulating and safety devices shall receive maintenance with due care to ensure that they function properly.
They may not be put out of action.
Before clearing the unit for use after maintenance or overhaul, check that operating pressures, temperatures and
time settings are correct and that the control and shut-down devices function correctly. If removed, check that the
coupling guard of the compressor drive shaft has been reinstalled.
Every time the separator element is renewed, examine the discharge pipe and the inside of the oil separator
vessel for carbon deposits; if excessive, the deposits should be removed.
Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering them, e.g.
when steam-cleaning.
Make sure that all sound-damping material, e.g. on the bodywork and in the air inlet and outlet systems of the
machine, is in good condition. If damaged, replace it by genuine Atlas Copco material to prevent the sound
pressure level from increasing.
Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
The following safety precautions are stressed when handling refrigerant:
a. Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use
breathing protection.
b. Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If
liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush abundantly
with fresh water over the clothing until all refrigerant is flushed away; then seek medical first aid.
c. Always wear safety glasses.
Protect hands to avoid injury from hot machine parts, e.g. during draining of oil.
NOTE: With stationary machine units driven by an internal combustion engine, allowance has to be made for extra safety
precautions, e.g. spark arrestors, fuelling care, etc. Consult Atlas Copco .
All responsibility for any damage or injury resulting from neglecting these
precautions, or by non-observance of ordinary caution and due care required in
handling, operating, maintenance or repair, even if not expressly mentioned in this
book, will be disclaimed by Atlas Copco.

Rev: 2 Page 8 of 27
7. Upgrade kits and content
The following table gives an overview of the kits:
AC partnumber Description
2230 5018 26 Upgrade kit ( FS & VSD)
2230 5018 27 Optional kit for options (1)
(1) See original service diagram :
Option 7 : ID integrated dryer
Option 12 : Energy recovery
Option 13 : DD filter ( only together with option 7 )
Option 14 : PT1000 motor protection in windings and bearings
Option 29 : Tube Coolers
Option 41 : Electronic oil bypass valve
7.1. Parts list 2230 5018 26 – MkIV to Mk5
MkIV to Mk5 Std

2230 5018 26
Partnumber Qty info
1630 2151 80 1 adapter plate
1630 0277 95 1 wire harness
1900 5200 22 1 Graphic +
0147 1170 03 4 mount Graphic +

1900 5200 33 1 IO2
1622 5099 04 1 IO2 cable
1622 0665 00 1 DIN-rail
1079 2263 01 2 Screws
0017 2016 59 10 dm earth cable
1088 0001 24 4 to mount earth cable
2230 0500 02 1 SMARTbox

9845 0231 00 1 CE
9845 1600 48 1 Service diagram FS
9845 1600 49 1 Service diagram VSD
9845 0284 00 1 Retrofit instruction

Rev: 2 Page 9 of 27
7.2. Parts list 2230 5018 27 – Optional kit
MkIV to Mk5 Optional
2230 5018 27
partnumber Quantity info
1900 5200 41 1 IO3-4
1622 5099 03 1 IO3 cable
1630 0277 96 1 wire harness
1622 0665 00 1 DIN-rail
1079 2263 01 2 Screws

Rev: 2 Page 10 of 27
8. Mechanical changes
When upgrading , the Mk5 module to be installed is an Mk5 Graphic+ controller with 5,7”
screen. An IO2 expansion module covering all I/O, is always needed.
Make sure the compressor is powerless! Disconnect the main switch.
8.1. Cubicle door

The Elektronikon Mk5 module can be mounted on the control cubicle a follows :
Detach the connectors from te MkIV master module .
Remove the MkIV module
Mount the Mk5 module on adapter 1630 2151 80 using the M4 bolts and washers.
Mount this assembly on the cubicle door using the M6 nuts and washers.
8.2. Expansion module(s) IO2
If no existing DIN rail is available , mount the delivered DIN rail 1622 0665 00 .
Mount the expansion module IO2
Provide earth connection between the master module , expansion module , the cubicle box and the cubicle door.
Use a yellow/green cable and 4 cable lugs to make 2 earth wires .
8.3. Expansion module IO34 .

Check the ideal position of the DIN rail 1622 0665 00 for the expansion module for easy
mounting of the IO34 modulesand wire connections .
Mount the expansion module IO34 on the delivered Din rail 1622 0665 00 .
Provide earth connection between the master module , expansion module , the cubicle box and the cubicle door.
Use a yellow/green cable and 4 cable lugs to make 2 earth wires .
8.4. Expansion module SPM . ( OPTIONAL ORDERING )
If the original compressor is equipped with SPM module ( E9-ACB5channel or E9-

ACB7channel ) , order following kits :
 If SPM module E9 - ACB7 : 2230 0053 00
 If SPM module E9 - ACB5 : 2230 0055 00
9. Electrical changes
Make sure if the compressor is powerless! Disconnect the main switch.

9.1. Wiring tool Mk5 Wago connectors
9.1.1. Plier tool Grey WAGO connector
PART NUMBER: DESCRIPTION:

2908 0093 00  Wiring tool for grey WAGO cage clamp
connectors
9.1.2. Tool Black WAGO connector

PART NUMBER:
-
DESCRIPTION:
 2,5x0,4mm flat screw driver
 Or order operating tool, No.210-719,
online from WAGO:
http://www.wagocatalog.com
9.2. Service diagrams

Mk5 converted service diagrams have been setup , started from the original MkIV service
diagrams :
9823 1821 xx
9823 1902 07 , -08 , -57 ,-58
These converted service diagrams can be used as guidelines for functionality of the
connections and the conversion.
Converted service diagrams Description

9845 1600 48 MkIV to Mk5 upgrades for Fixed speed units
9845 1600 49 MkIV to Mk5 upgrades for VSD units
9.3. Rewiring
Wire harnesses are created to make an easy connection from MkIV to Mk5 module.
Wire harnesses Description

1630 0277 95 MkIV to Mk5 upgrades basic
1630 0277 96 MkIV to Mk5 upgrades with IO3-4 module
9.3.1. Wiring tables
Depending on the version / production date of the original unit , some extra rewiring needs
to be executed on the wire harness
Refer to original service diagram partnumber for changes to be done :
Extra rewiring For service diagrams

GA 180 VSD 9823 1821-40 /-41
GA 315 VSD 9823 1821-31/-32 ; 9823 1821-35/-36 ; 9823
GA 90- 160 + 1821-61/-62
9823 1902-07/-08
GA 110-132-160 VSD 9823 1902-57/-58

GA 110-132-160 VSD ( >2009)
GA 90-110-132-160 ( >2009)
wire from connector / pin

GA180 VSD ( <2009)
GA315 VSD ( <2009)
wire to connector / pin
X 2x8/1 → 2x8/5 only with sd 9823 1821-61/-62

X 2x8/2 → 2x8/6 only with sd 9823 1821-61/-62
X 2x9/6 → 2x9/9
X X X 2x9/10 → 2x9/5
X 3x33/7 → 3x33/14
X X X 6x9/4 → 2x9/12
X X X 2x9/12 → 2x9/10
X X 6x9/3 → 2x9/9
X X X 2x10/2 → 2x11/4
X X X 2x10/3 → 2x11/5
X X 2x11/7 → 2x10/2
X X 2x11/8 to → 2x10/3
X 2x10.1/1 → 2x10.1/4
X 2x10.1/2 → 2x10.1/5
X 2x10.1/4 → 2x10.1/7
X 2x10.1/5 → 2x10.1/8
X 2x10.2/2 → 2x10.1/2
X 2x10.2/3 → 2x10.1/3
On Fixed Speed units digital inputs in the Mk4 version were serial connected . In Mk5
version these should be split up :
Mk5 3x33/16 for Q41 ; Mk5 3x33/15 for Q40
Mk5 3x33/20 for LSHL17 ; Mk5 3x33/19 for LSHL47

9.4. Download instruction
While downloading with Speci 5 program fill in:

 Correct model and Generation ( see chapter 8.4.1.)
 Serial number of the compressor

 All active counters: e.g. running hours , loaded hours, motor starts, load relay, dryers starts, fan starts, .
..
Not entering serial number, running hours & service intervals in a proper way will influence
appearance of the machine in SMARTLINK. Incorrect information will impact operational
efficiency & customer satisfaction.
After downloading, check on module screen if the correct service plan levels (running hours

and real time hours) of the retrofitted unit are downloaded in the controller.
* Menu > Service plan > Service plan :
Mk5 data files are available for upgrades in the LN Elektronikon database.
9.4.1. Selection of data files for MkIV to Mk5 upgrades

Fixed speed units
model gen generation description
GR110A2 1 Mk5 upgrades on GR110 gen1

GA90_125P 1 GA90 Modular gen 1

GA90BR 1 GA90 Modular Brazil gen 1
GA110_150 1 GA110 Modular gen1

GA110-150P 1 GA110+ Modular gen1
GA110BR 1 GA110 Modulare Brazil gen1
GA132_175P 1 GA132+ Modular gen1






GA90 1 old GA size 1

GA200 1 Twin size 2 GA
GA250 1 Twin size 2 GA
GA315 1 Only 60 Hz. ( Twin size 2 )

GA200 2 Twin size 2 GA gen2

GA250 2 Twin size 2 GA gen2
GA315 2 Only 60 hz ( Twin Size 2) gen2
G200 1 G200 gen1

G250 1 G250 gen1
G200 2 G200 gen2

G250 2 G250 gen2
GA160_1 1 GA160 modulare gen1

GA355_1 1 GA355gen1
GA400_1 1 GA400gen1
GA450_1 1 GA450gen1
GA500_1 1 GA500gen1
VSD units : read also remark in chapter 4 concerning Spider - Bowex coupling
Model Gen generation description

Mk5 upgrades on GA132VSDBR Brazil gen 0
GA132VSDBR 0 ( Siemens MM converter - SPIDER COUPLING )

Mk5 upgrades on GA160VSDBR Brazil gen 0
GA160VSDBR 0 ( Siemens MM converter - SPIDER COUPLING )
Mk5 upgrades on GA 132 VSD gen 1 from APF134126
GA132VSD_1 1 ( ABB converter - SPIDER COUPLING )
Mk5 upgrades on GA 160 VSD gen 1 from APF134126
GA160VSD_1 1 ( ABB converter -SPIDER COUPLING )
Mk5 upgrades on GA110VSD modular gen 1

GA110VSD_1 2 ( ABB converter -BOWEX COUPLING - no TT85)
Mk5 upgrades on GA110VSD modular gen 2&4
GA110VSD_1 4 ( ABB converter -BOWEX COUPLING)
Mk5 upgrades on GA132VSDBR Modular Brazil gen 4
GA132VSDBR 4 (WEG converter -BOWEX COUPLING)
Mk5 upgrades on GA132VSDBR Modular Brazil gen 2
GA132VSDBR 2 (Siemens MM converter -BOWEX COUPLING )
Mk5 upgrades on GA132VSD modular gen4
GA132VSD_1 2 ( ABB converter -BOWEX COUPLING - no TT85 )
Mk5 upgrades on GA132VSD modular gen3&4
GA132VSD_1 4 ( ABB converter -BOWEX COUPLING)
Model Gen generation description

Mk5 upgrades on GA160VSDBR Modular Brazil gen4
GA160VSDBR 4 ( WEG converter -BOWEX COUPLING )

Mk5 upgrades on GA160VSDBR Modular Brazil gen2
GA160VSDBR 2 ( Siemens MM converter -BOWEX COUPLING )
Mk5 upgrades on GA160VSD modular gen2
GA160VSD_1 2 ( ABB converter --BOWEX COUPLING - no TT85)
Mk5 upgrades on GA160VSD modular gen 3&4
GA160VSD_1 4 ( ABB converter --BOWEX COUPLING )
GA132VSD 1 Mk5 upgrades on GA132 VSD gen1 < APF134125

GA180VSD 1 Mk5 upgrades on GA180 VSD gen1 < APF134125
GA180VSDWG 1 Mk5 upgrades on GA180 VSD gen1 Brasil version (WEG converter)
GA315VSD 1 Mk5 upgrades on GA315VSD < AIF107519 ( VACON converter )
GA315VSD_1 1 Mk5 upgrades on GA315VSD >AIF107786 ( SINAMIC 130 converter )
GA132VSD 2 Mk5 upgrades on GA132 VSD gen2 < APF134125 with ASCO valve
GA180VSD 2 Mk5 upgrades on GA132 VSD gen2 < APF134125 with ASCO valve
GA180VSDWG 2 Mk5 upgrades on GA180 VSD Brasil version (WEG converter)
GA315VSD 2 Mk5 upgardes on GA315 VSD (VACON converter ) - with ASCO valve
Mk5 upgrades on GA315 VSD prod>1/1/2012 (SINAMIC130 converter) -
GA315VSD_1 2 with ASCO valve
Open in Speci5 the correct database : 9845 1601 36

Select the correct model and parameter configuration according to list beneath :

Do not forget to fill in the serial number of the upgraded compressor !
After downloading , check if the service plan is correct (


10. Powerless test instruction
10.1. First step
Make sure the compressor is powerless! Disconnect the power switch.

Use the original service diagram and the conversion lists.
10.2. Adapted connections
Special attention for adapted connections must be given to: (if present)
 Emergency stop contact S2 to 3X33/4 (DI 01)
 Overload motor contact F21/fanmotor Q15/Q16 to 3X33/7 (DI 06)
 Starter feedback contact K21(DOL) , K23(Y-D) to 3X33/9 (DI08)
 Overload fanmotor(s) contact Q25/Q26 to 3X33/10
 Overload dryer fans contact Q41/F41/F42 to 3x33/16
 Overload dryer contact Q40 to 3x33/15
 High pressure shutdown dryer K40 to 3x33/18
 Temperature sensor connections according to service diagram 9845 1600 48 or 9845 1600 49
 Pressure sensor connections according to service diagram 9845 1600 48 or 9845 1600 49
10.3. Double-check
Go for the second time through the conversion lists and check:
 If you have put the right wire on the right terminal
 If you have made a correct connection
 If the terminal is fixed in the Mk5 Elektronikon

11. Powered test instruction
11.1. First step

 Make sure the compressor is powered. Connect the main switch.
Do not push the start button at this moment.
Use the original service diagram and the conversion lists.
11.2. Sensor + input test

 Check all analogue inputs for their correct read out and connecting.
- Disconnect, one by one, the connectors from each sensor.

- Check if the Mk5 display gives the message ‘sensor error’.
- Reconnect all plugs one by one and check if the protection message disappears.
Check all safety devices for their functionality.
- Simulate temperature- and pressure warnings and shutdowns.
Check all digital inputs with the appropriate message on the MK5.
- Push emergency stop button S2 and check if the “emergency stop“ signal appears
on the Mk5 display.
- Unlatch emergency stop button S2 and reset the Mk5 controller. Check if the
shutdown message disappears.
Switch off all present circuit breakers Q.. one by one and check if an overload
-
message appears on the Mk5 display.
- Switch back on circuit breaker Q.. and reset the Mk5 controller. Check if the
overload message disappears
11.3. Start with the power lines connected

 Start the compressor, keeping one hand on the emergency stop button.

Check if the compressor is running normal: sequence of elements + proper working of all fans.
 Check the read out on the MK5.
Put the correct upgrade service diagram and this instruction next to the original in the
cubicle.

12. Clean up documentation
12.1. Wire harnesses

 Be sure all the original connectors of the sensors, actors and other equipment are
connected to a connector of the wire harness. If not, do check again (see: Error!
eference source not found. Error! Reference source not found.).
 Remove the connectors and corresponding wiring of the wire harness that are not
used.
Note: The wire harnesses are made to support all options and features for the
complete range. It is possible that not all of the connectors of the wire harness
are used.
 Clamp the wire harness with some cable ties
12.2. Service diagrams and instructions
 Mark all the changes according to the manual rewiring and clean-up on the MkIV  Mk5 upgrade
service diagram.
 Mark-up the MkIV and the expansion modules on the original service diagram and refer to the MkIV 
Mk5 upgrade service diagram.
Example:
 Put the updated MkIV  Mk5 upgrade service diagram, the marked MkIV service diagram and this
instruction next to the original documents in the cubicle.

13. Installation of SMARTBOX
 Remove covers.  Determine antenna position.  Position should be equally divided.

The position should be:
 on a single metal
sheet.
 close enough to the
electrical cubicle for the
length of the antenna
cable.
 Drill hole.  Remove burrs.  Guide antenna cable through the

Work in a clean way, collect and hole.
remove all particles and dust.
 Mount antenna.  Mount the antenna on the roof using the delivered tooth lock washer. This
washer will remove the paint to have a good earth/ground connection. The
tooth lock washer has only one side with sharp edges. It is important that the
sharp side is positioned towards the painted roof.

This is important to achieve a good network sensitivity and to avoid
interferences that may have an impact on other electronic equipment.
Using this improves safety.
 Guide through compressor  There may be no interference with  Drill hole: position.
towards electrical cubicle. other cables.
Routing: use available cutouts as
much as possible.

 Drill hole: work in a clean way,  Guide cable in cubicle.  Mount cable gland.
make sure the electrical cubicle is
free of iron particles and dust.
 Mount SMARTBOX.  Mount 24VAC-VDC power supply.  Plug 24VAC connector in power
Connect SMARTBOX to power supply. Wire connector to 24VAC
supply. transformer connection
 Connect antenna cable.  Antenna cable is clear from other  Connect ethernet cable to
cables, without interference. Elektronikon.
 Clean the unit.  Power on.  Check the LED’s.

Startup takes max. 15 minutes.

 Green LED flashing or always on:  Yellow LED flashing or always on:  Red LED flashing every 2 sec.:
communication with communication with mobile communication = OK.
Elektronikon = OK. Elektronikon = OK.
 If Red LED is always ON  The unit is ready for

= NOT OK! SMARTLINK.


MK4 To MK5 Upgradation Instructions

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MK4 To MK5 Upgradation Instructions

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Upgrade Instruction

Mk5 Upgrade Instruction

Printed Matter Number : 9845 0284 00 ed02

Document no.: 9845028400-01 Issue date: 5/22/2017 4:35:12 PM

Document no.: 9845028400-01 Issue date: 5/22/2017 4:35:12 PM

Document no.: 9845028400-01

Serial numbers <APF152161 and S996321,S997103,S997679,S998374 have Spider

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All kits will include the SMARTBOX kit :

- see chapter 13 to install the SMARTBOX ( = PM 2946 1650 xx)

Before starting the upgrade write down:

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Document no.: 9845028400-01 Issue date: 5/22/2017 4:35:12 PM

checks. Wear ear protectors when opening a door.

e. All electrical leads are secure and in good order

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If performing any operation involving heat, flames or sparks on a machine, the

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7.1. Parts list 2230 5018 26 – MkIV to Mk5

MkIV to Mk5 Std

0301 2321 00 6 mount Graphic +

2230 0500 02 1 SMARTbox

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Document no.: 9845028400-01 Issue date: 5/22/2017 4:35:12 PM

8.1. Cubicle door

8.2. Expansion module(s) IO2

8.3. Expansion module IO34 .

8.4. Expansion module SPM . ( OPTIONAL ORDERING )

If the original compressor is equipped with SPM module ( E9-ACB5channel or E9-

 If SPM module E9 - ACB5 : 2230 0055 00

Make sure if the compressor is powerless! Disconnect the main switch.

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9.1.1. Plier tool Grey WAGO connector

PART NUMBER: DESCRIPTION:

9.1.2. Tool Black WAGO connector

9.2. Service diagrams

Converted service diagrams Description

Wire harnesses Description

Document no.: 9845028400-01 Issue date: 5/22/2017 4:35:12 PM

9.3.1. Wiring tables

Refer to original service diagram partnumber for changes to be done :

Extra rewiring For service diagrams

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wire from connector / pin

wire to connector / pin

X 2x8/1 → 2x8/5 only with sd 9823 1821-61/-62

Mk5 3x33/16 for Q41 ; Mk5 3x33/15 for Q40

Mk5 3x33/20 for LSHL17 ; Mk5 3x33/19 for LSHL47

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While downloading with Speci 5 program fill in:

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Document no.: 9845028400-01 Issue date: 5/22/2017 4:35:12 PM

9.4.1. Selection of data files for MkIV to Mk5 upgrades

GR110A2 2 Mk5 upgrades on GR110 gen2

GA90_125P 1 GA90 Modular gen 1

GA110_150 1 GA110 Modular gen1

GA160_200P 1 GA160+ Modular gen1

GA90_125P 2 GA90 Modular gen 2

model gen generation description

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GA90_125P 4 GA90 Modular gen 4

GA90_125P 5 GA90 Modular gen 5

GA132BR 5 GA132 Modulare Brazil gen5