ECOS

Description of System

GMK 5100
GMK 5180
GMK 5200
GMK 6200-1
GMK 6220(L)
GMK 6250
GMK 6300

ERROR CODES
TK4, 8.05. 2000
1 GENERAL DESCRIPTION .......................................................................................... 1
1.1 DIGITAL INPUT SIGNALS ................................................................................................ 1
1.2 ANALOGUE INPUT SIGNALS ........................................................................................... 2
1.3 DIGITAL OUTPUTS ......................................................................................................... 2
1.4 PWM OUTPUTS ............................................................................................................. 3
1.5 CONTROL LEVERS.......................................................................................................... 3
1.6 PRECISION LENGTH SENSOR (TELESCOPE CYLINDER)..................................................... 3
1.7 EKS 4 RCI (RATED CAPACITY INDICATOR)................................................................... 4
1.8 ECOS ............................................................................................................................ 4

2 PRESENTATION OF THE ERROR MESSAGES ..................................................... 5

2.1 MEANING OF THE ERROR CODE ..................................................................................... 5
2.1.1 Digital Inputs ........................................................................................................... 5
2.1.2 Digital Output .......................................................................................................... 5
2.1.3 PWM Output ............................................................................................................ 5
2.1.4 Analogue Input......................................................................................................... 5
2.1.5 Control Levers (J3501, J3502) ................................................................................ 5
2.1.6 Control System Error Message (ECOS) .................................................................. 6
2.1.6.1Auxiliary Drive Units Logic Error:.............................................................................................. 6
2.1.6.2Pinning System Logic Error......................................................................................................... 6
2.1.7 Precision Length Sensor (A3502) ............................................................................ 7
2.1.8 EKS 4 RCI (A100).................................................................................................... 7
2.2 MEANING OF THE STATUS .............................................................................................. 7

3 CONTROL SYSTEM (ECOS)ERROR MESSAGES ................................................. 8

3.1 AUXILIARY DRIVE LOGIC ERRORS ................................................................................. 8
3.2 PINNING SYSTEM LOGIC ERRORS ................................................................................... 9

4 EXAMPLES................................................................................................................... 11
4.1 SYSTEM ERROR MESSAGE ........................................................................................... 11
4.2 SLEWING SYSTEM ERROR MESSAGE ............................................................................ 11
4.3 MAIN HOIST SYSTEM ERROR MESSAGE....................................................................... 11

5 EMERGENCY OPERATION SUBMENU ................................................................ 12

ECOS ERROR CODE TABLES

Part of the ECOS design criteria is to monitor externally connected components such as digital inputs from proximity switches and outputs to solenoid
valves etc. Any system defects will be shown with a text message and bit code on the ECOS display. To accurately determine the error it is important
to have the following from the displayed error message:

1. The drive / group identification

2. The component reference & group error code

3. The Status error code

By referring this information to the following tables we can identify the error as:
Main hoist system
Source of the error : Y1104
Cause (00000010) : Short to ground
Status reference : Output signal
 Description of System Page 1
Error Codes

1 General Description
The ECOS system design makes it possible to monitor the sensors, control elements and
installations associated with the system electrically.

1.1 Digital Input Signals

The digital input signals are evaluated via resistor boards. The resistor boards produces a
voltage from the 0V or 24V input signal, which is then, routed into the ECOS units.

0V → 2.3V (residual voltage level at ECOS input derived from open switch)
24V → 4.6V (residual voltage level at ECOS input derived from closed switch)

This voltage is routed to the digital input of ECOS, where it is detected with an A-D
converter and evaluated.

ECOS can detect the following states from the information:

¾ Short circuit against ground = 0 ... 1.1V,

Internal values

¾ High = 1.1V ... 3.3V,

¾ Low = 3.3V ... 6.35V,

¾ Short circuit against 24V or cable break = 6.35V .. 8.5V.

24V Battery supply

Resistor Board Connection Principle.

ECOS

Digital input values

The test meter would indicate the following values:

0 1.1 V = Short to ground Note: If a cable break were to

occur between the voltmeter
1.1 3.3 V = Switch open
and the resistor board, the
3.3 6.35 V = Switch closed measured value would be
6.35 24 V = Cable break/short to battery voltage approximately 7.2 volts.
 Description of System Page 2
Error Codes
1.2 Analogue Input Signals
The evaluation of the analogue input signals is similar to that for the digital input signals.

The sensor supplies a current in the range from 4mA ... 20mA. This current flows into
ECOS and causes a voltage drop at a measuring resistor (260 Ohm). This voltage is read
and evaluated by an A-D converter. ECOS can detect the following states from the
information:

¾ Short circuit against ground or cable break = 0 ... 1.0V,

¾ Measured value = 1.0V ... 5.2V,
¾ Short circuit to battery 24V = 5.2V .. 8,5 V.

1.3 Digital Outputs

The digital outputs are switched on by transistors, which have current detection. The
current detection gives an output signal, if the current through the transistor is greater
than 100mA. In addition, it is possible to compare the nominal and actual values of the
output.

A matrix can be produced from this information, which provides information about the
condition of the digital output.

Nominal Actual Current State

value value detection
OFF OFF OFF OFF
ON ON OFF Cable break or short circuit 24V
ON OFF ON Short to ground
ON ON ON ON
Note: if a consumer is connected, which requires less than 100mA current (signal lamp),
the cable break/short circuit 24V error for this output will be deactivated.
 Description of System Page 3
Error Codes

1.4 PWM Outputs

PWM outputs can be used as standard digital outputs or as analogue outputs with an
adjustable output current.

The fact that the output current can be measured means that the error evaluation can be
extended with respect to the digital outputs. The following errors are detected by ECOS:

¾ Short to ground,

¾ Short circuit to 24V,

¾ Cable break,

¾ Low resistance,

¾ High resistance.

1.5 Control Levers

The control levers combine digital and analogue inputs. Evaluation of the control levers is
more complex under these conditions. In addition to the normal error messages,
mechanical errors are also evaluated. A mechanical error is detected if the directional
signals coming from the control lever are contradictory.

1.6 Precision Length Sensor (telescope cylinder)

The precision length sensor is a system, which is connected with ECOS via CAN Bus.
ECOS can detect the following errors:

¾ No data connection with the length sensor.

¾ Hardware error of the length sensor.

 Description of System Page 4
Error Codes

1.7 EKS 4 RCI (Rated capacity indicator)

EKS 4 is a system, which is connected with ECOS via CAN Bus. ECOS can detect the
following errors:

¾ No communication with the RCI regarding date, time and measured values.

¾ No response from the RCI to automatic telescoping system input.

1.8 ECOS
The locking control system and the auxiliary drive units are monitored by ECOS.
ECOS can detect and output the following errors:

¾ Incorrect telescope status,

¾ Operating condition of the telescoping cylinder not conclusive (logic),

¾ Proximity switch of the counterweight lock not conclusive (logic),

¾ Proximity switch for detecting the position of the counterweight not conclusive
(logic),

¾ Proximity switch for detecting the position of the turntable lock not conclusive
(logic).
 Description of System Page 5
Error Codes

2 Presentation of the Error Messages

An error is identified by the element, which triggered the error, the error code and the
status, which relates to the function of the element.

The error code and the status are coded in binary format, each digit having a particular
meaning.

2.1 Meaning of the Error Code

2.1.1 Digital Inputs

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
na na na na na na Short circuit to Cable break/
ground 24V short
circuit

2.1.2 Digital Output

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
na na na na na na Short circuit to Cable break/
ground 24V short
circuit

2.1.3 PWM Output

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
na na na High Low resistance Cable break Short circuit to 24V short
resistance ground circuit

2.1.4 Analogue Input

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
na na na na na na Short circuit to 24V short
ground/Cable circuit
break

2.1.5 Control Levers (J3501, J3502)

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
na Mechanical Direction (-) Direction (-) Direction (+) Direction (+) I > 5 mA I < 4mA
error 24V short Short circuit to 24V short Short circuit to
circuit ground/ Cable circuit ground/ Cable
break break
 Description of System Page 6
Error Codes

2.1.6 Control System Error Message (ECOS)

2.1.6.1 Auxiliary Drive Units Logic Error:

a) Proximity switches of the counterweight locking are not conclusive

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
PS right PS left PS right PS left 0 0 0 1
cylinder cylinder cylinder cylinder
unlocked unlocked locked locked

b) Proximity switches for detecting the position of the counterweight are not conclusive
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
PS right PS left PS right PS left 0 0 1 0
cylinder cylinder cylinder cylinder
up up down down

c) Proximity switches for detecting the position of the turntable lock are not conclusive
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
na na PS PS 0 1 0 0
turntable turntable
locked unlocked

2.1.6.2 Pinning System Logic Error

a) Proximity switches for detecting the locking condition of the telescope pinning system
are not conclusive
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
PS PS PS PS 0 0 0 1
Boom section boom section telescoping telescoping
locked unlocked cylinder cylinder
locked unlocked

b) Telescope status error: telescope status contains invalid values

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 0 0 1 1 0 0 0

c) Telescope status error: It was not possible to find a pinning position using the signal
from the precision length sensor and the telescope status.
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 0 1 0 1 0 0 0
 Description of System Page 7
Error Codes
d) Telescope status error: Telescope status does not correspond with the current operating
condition
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 0 1 1 1 0 0 0

e) Telescope status error: “Too high” and “too low” signals of the proximity switches do
not correspond with the operating condition
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 1 0 0 1 0 0 0

2.1.7 Precision Length Sensor (A3502)

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
na na na na na na Hardware error No data
received

2.1.8 EKS 4 RCI (A100)

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
na na na na na na No data No data
received for received
telescoping Current
date/time etc.

Note: The letters na within a Bit description box indicate not applicable

2.2 Meaning of the Status

Status Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Control levers X

Digital input X

Output X

Analogue input X

CAN Bus X

Reserve 1 X

Mechanical X

Operating status X
 Description of System Page 8
Error Codes

3 Control system (ECOS)Error messages

The error message system has been expanded to cover a wider range of contingincies with
paticular referenceto Auxiliary Drive Logic Errors and Pinning System Logic Errors. The
structure of the Bit information now carries specific error identity and may or may not
include proximity switch (PS) function descriptions. See: 2.1.6.1 a - c & 2.1.6.2 a - e.

3.1 Auxiliary Drive Logic Errors

Example: the right aligned Bit 0, flagged with 1 for the Auxiliary Drive Logic Errors
identifies it as: a) Proximity switches of the counterweight locking are not conclusive .
Bit 4 –Bit 7 carries the proximity switch descriptions.

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

PS right PS left PS right PS left 0 0 0 1
cylinder cylinder cylinder cylinder
unlocked unlocked locked locked

This function identity continues for Auxiliary Drive Logic Errors with Bit 1 being flagged
with 1 for: b) Proximity switches for detecting the position of the counterweight are not
conclusive. Bit 2 is flagged with 1 to identify: c) Proximity switches for detecting the
position of the turntable lock are not conclusive with respective proximity switch
functions.

It is therefore most important to have the correct error description e.g. AUXILIARY
DRIVE with error source e.g.ECOS and code e.g. 10100001 to correctly identify 2.1.6.1
a) as the correct information source to enable corrective action.
 Description of System Page 9
Error Codes

3.2 Pinning System Logic Errors

A similar format is used for Pinning System Logic Errors (2.1.6.2) for: a) Proximity
switches for detecting the locking condition of the telescope pinning system are not
conclusive
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
PS PS PS PS 0 0 0 1
Boom section boom section telescoping telescoping
locked unlocked cylinder cylinder
locked unlocked

01110001

Typical Error Display

PINNING SYSTEM
ERROR MESSAGE
ECOS 01110001
STATUS 10000000
Error message relates to : Pinning system
Source of the error : ECOS
Cause (01110001) : Locking condition of the Pinning system
not conclusive
(Boom section is unlocked, telescoping cylinder is
not completely locked)
Status reference : Operating status

Additional Pinning System Logic Errors (2.1.6.2, b – e) only carry flagged Bit codes to
identify Telescope Status Errors.

Example:
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
0 1 0 0 1 0 0 0

Matching the Bit code to the available selection (2.1.6.2, b – e) then identifies the error
as: e) Telescope status error: “Too high” and “too low” signals of the proximity switches
do not correspond with the operating condition

The program logic within ECOS requires that at least one of the signals must be present
when the telescope cylinder/boom section is locked. The above error would then require
you to focus on the missing input signal(s) to effect a repair.
Description of System Page 10
Error Codes
 Description of System Page 11
Error Codes

4 Examples

4.1 System Error Message

SYSTEM
ERROR MESSAGE
A3502 00000001
STATUS 00010000
Error message relates to : System
Source of the error : A3502
Cause (00000001) : No data received
Status reference : CAN Bus

4.2 Slewing System Error Message

SLEWING SYSTEM
ERROR MESSAGE
Y2301 00000100
STATUS 00000100
Error message relates to : Slewing system
Source of the error : Y2301
Cause (00000100) : Cable break
Status reference : Output signal

4.3 Main Hoist System Error Message

MAIN HOIST SYSTEM
ERROR MESSAGE
Y1104 00000010
STATUS 00000100
Error message relates to : Main hoist system
Source of the error : Y1104
Cause (00000010) : Short to ground
Status reference : Output signal

Note: With regard to digital outputs: if the Bit code exceeds Bit 2 it then indicates that
this must be a PWM output error as standard outputs errors do not exceed Bit 1. See 1.3
& 1.4.
 Description of System Page 12
Error Codes

5 Emergency Operation submenu

If a displayed error is confirmed with the enter key and it covers one of the following:

¾ Precision length sensor

¾ Telescope cylinder proximity switch circuits for locking functions
¾ Telescope cylinder (cylinder mounted) solenoid valves

Example of error message

ERROR MESSAGE
PINNING SYSTEM
A3502 00000001
STATUS 00010000

This will cause the ECOS display to prompt for a Keycode: once the Keycode is entered
ECOS will select EMERGENCY OPERATION, telescoping mode. The status in the
second line will show a three-digit code to inform you of the type of error:

¾ 0 0 1 = Precision length sensor

¾ 0 1 0 = Cylinder proximity switches / locking logic
¾ 1 0 0 = Cylinder solenoid valves

Multiple errors would be seen as a simultaneous display of the digit 1

If the first digit is flagged with 1 it will not be possible to operate the pinning system. See
section 14, chapters 14.5.5 – 14.5.7 (Malfunctions on the superstructure) in the operator’s
manual for further details.

TELESCOPING

STATUS: 0 0 1

EMERGENCY OPERATION

T: 180 s L:8.40 ft

Example of ECOS display in EMERGENCY mode

 Display Example
ERROR MESSAGE STATUS GROUP
SYSTEM ERROR ERROR
CAUSE OF ERROR CORRECTIVE ACTION
GROUPS CODES
A3502: 00000001
STATUS 00010000

STATUS
Analogue threshold output of
control lever is outside
parameters:
00000001 I < 4mA The control lever emergency program will be
00000010 I > 5mA active with any of the listed errors. This will allow
00000100 Direction + limited functionality to allow crane derigging.
Control lever Short to ground/cable break
00000001
J3501 or J3502 00001000 Direction + Swap control levers to determine whether fault is
24V short internal or external. If internal, replace control
00010000 Direction – lever assembly. If external, check all cables &
Short to ground/cable break connections to determine cause.
00100000 Direction –
24V short
01000000 Mechanical error
Precision length 00000001 No data reception Check cable connections to CAN hub
indicator: A3502 00000010 Hardware error Replace length sensor
00010000
Communication 00000001 No data reception Check EKS 4 functionality & verify
with EKS 4: A100 00000010 No data reception (telescope) communication address is set correctly.
 STATUS GROUP CAUSE OF ERROR
STATUS ERROR ERROR CORRECTIVE ACTION
GROUPS CODES PS = Proximity switch
Counterweight logic error
“PS right cyl locked” is active
10100001
and “PS right cyl unlocked” is
active
Counterweight logic error
01010001 “PS left cyl locked” is active and
Check actual position of counterweight
“PS left cyl unlocked” is active
cylinders to determine which proximity switch
Auxiliary Drive Counterweight logic error
is giving an invalid signal. Check proximity
Gear 10100010 “PS right cyl up” is active and
switch function & cables/cable routing to
ECOS “PS right cyl down” is active
determine source of invalid signal.
Counterweight logic error
Replace switch/cables as necessary.
01010010 “PS left cyl up” is active and “PS
left cyl down” is active
Next page

Turntable pinning logic error

10000000 “PS turntable locked” is active
00110100
and “PS turntable unlocked” is
active
None of the telescope cylinder
00000001 Check boom cable connections
PS’s are active
“PS boom unlocked” is active Error acknowledgement will activate the
01000001 and “PS telescope cylinder Emergency mode mask
locked” is inactive
Locking System
“PS boom locked” is active and Check actual position of locking mechanism on
Logic errors 11000001
“PS boom unlocked” is active telescope cylinder to determine which
ECOS
proximity switch is giving an invalid signal.
Check proximity switch function &
“PS boom locked” & “PS boom
11100001 cables/cable routing to determine source of
unlocked” are both active
invalid signal.
Replace switch/cables as necessary.
 STATUS GROUP
STATUS ERROR ERROR CAUSE OF ERROR CORRECTIVE ACTION
GROUPS CODES
“PS telescope cylinder unlocked”
00010001 is active and “PS boom locked” is
inactive
“PS telescope cylinder locked” is
00110001 active and “PS telescope cylinder
unlocked” is active
“PS boom unlocked” is active
01010001 and “PS telescope cylinder
unlocked” is active
“PS boom unlocked” is active
01110001 and “PS telescope cylinder Error acknowledgement will activate the
locked” and “PS telescope Emergency mode mask.
cylinder unlocked are both active.
Next page

“PS boom locked” is active and Check actual position of locking mechanism on
Locking System
“PS telescope cylinder locked” telescope cylinder to determine which
10000000 Logic errors 10110001
and “PS telescope cylinder proximity switch is giving an invalid signal.
ECOS
unlocked are both active. Check proximity switch function &
“PS boom locked” is active and cables/cable routing to determine source of
“PS boom unlocked” is active invalid/missing signal.
11010001
and “PS telescope cylinder Replace switch/cables as necessary
unlocked” is active
“PS telescope cylinder locked”
00100001 is active, but only from a single
switch.
“PS boom unlocked" is active and
“PS telescope cylinder locked”
01100001
is active, but only from a single
switch.
All of the telescope cylinder PS’s
11110001
are active
 STATUS GROUP
STATUS ERROR ERROR CAUSE OF ERROR CORRECTIVE ACTION
GROUPS CODES
Telescope status error: Telescope System will default to ‘Set telescope status’.
00011000 status contains invalid values:
e.g. section 1 is not at 0% and Verify & enter correct telescope status &
section 2 is unlocked confirm
Telescope status error: System will default to ‘Set telescope status’.
It was not possible to find a
00101000 pinning position using the signal Check telescope status is correct
from the precision length sensor Check precision length sensor values
and the telescope status Check length parameters
Next page

Locking System
10000000 System will default to ‘Set telescope status’. In
Logic errors
the modes TLSL, TUSL & TMSL ‘section
ECOS Telescope status error: Telescope
locked’ signals must exist. In the modes TLSU
00111000 status does not correspond with
& TLSM one ‘section unlocked’ signal must
the current operating condition
exist. Check ‘PS’ functions and wiring circuits
to ECOS.
Telescope status error: System will default to ‘Set telescope status’. In
Too high & too low signals of the the modes TLSL, TLSU & TLSM one of the
01001000 proximity switches do not signals ‘too high’ or ‘too low’ must exist.
correspond with the operating Check ‘PS’ functions and wiring circuits to
condition ECOS.
 MAIN MENU

STATUS GROUP
STATUS ERROR ERROR CAUSE OF ERROR CORRECTIVE ACTION
GROUPS CODES
00000001 Cable break/24V short Check cable connections between ECOS &
00000010 Digital input 00000010 Short to ground resistor boards

00000001 Cable break/24V short

00000010 Check cable connections between ECOS &
Short to ground
solenoid valve
00000100 Output 00000100 Cable break
00001000 Low resistance Check cable connections between ECOS &
00010000 High resistance solenoid valve. Check solenoid specification

00000001 24V short Check cable connections between ECOS &

00001000 Analogue input 00000010 Cable break / short to ground transducer.