ECOS Error Codes TMS 9000E

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ECOS
System Description
TMS 9000E
Error Codes
Valid as of ECOS Version 01.00.00
Jens Wessels
TK4, 30.03.2007
Table of Contents
1 GENERAL DESCRIPTION .......................................................................................... 1
1.1 LIST OF DEVICES ........................................................................................................... 1
1.2 LIST OF GROUPS ............................................................................................................ 2
1.3 POSSIBLE ERRORS.......................................................................................................... 3
2 LIST OF COMPONENTS.............................................................................................. 4
2.1 DIGITAL INPUTS (GROUP NUMBER 1) ............................................................................ 4
2.1.1 Digital Inputs of ESX 0..2 ........................................................................................ 4
2.1.2 Outputs of ESX 0..2.................................................................................................. 5
2.1.3 Analogue Inputs of ESX 0..2 .................................................................................... 6
2.2 IO - CARD ...................................................................................................................... 6
2.2.1 Analogue Inputs of IO - card 0..1 ............................................................................ 6
2.2.2 Digital Inputs and Outputs of IO - card 0..1 ........................................................... 7
2.3 JOYSTICK ERRORS ......................................................................................................... 8
2.4 ECOS ERRORS (DEVICE NUMBER 25) ........................................................................... 9
2.4.1 Change-over Contact Group (Group Number 12)................................................... 9
2.4.2 Pinning System Group (Group Number 16) ............................................................ 9
2.4.2.1 Explanations regarding Error Message 25.16.3.n...................................................................... 11
2.4.3 System Monitoring Group (Group Number 18)..................................................... 12
2.4.4 Main Hoist Group (Group Number 20) ................................................................. 14
2.4.5 Auxiliary Hoist Group (Group Number 21)........................................................... 14
2.4.6 Derricking Group (Group Number 22).................................................................. 15
2.4.7 Telescoping Group (Group Number 23)................................................................ 15
2.4.8 Slewing Group (Group Number 24) ...................................................................... 15
2.4.9 Can-Bus Error ....................................................................................................... 16
2.5 DEVICE STAND ALONE (ERROR CAN BUS) ................................................................. 23
3 ASSIGNMENT OF THE ESX ..................................................................................... 24
System Description TMS 9000E Page 1
Error Codes
1 General Description
The ECOS offers the possibility of electrically monitoring the sensors, actuators and equipment
connected to the system. The error message produced by ECOS consists of four figure displays,
which can be any value between 0 and 255. A new error message is indicated by a flashing warning
triangle and can be displayed via the function key [?].The number code is constructed as follows:
XXX – XXX – XXX – XXX
Error number
Index
Group number
Device number
The allocation of device and group is the same for all error messages. Index and error number can be
used as an extended error message for certain devices. In this case, no figure appears in the display
for the index and/or no figure appears for the error number.
1.1 List of Devices
Device-No. Device Fig. Device-No. Device Fig.
1 ESX 0 19 LMI
2 ESX 1 20 Position length sensor
3 ESX 2 21 Display
9 IO 0 24 Slope sensor
10 IO 1 25 ECOS
17 Joystick left 43 Stand Alone
18 Joystick right
Error Codes
1.2 List of Groups
Group -No. Group Fig. Notes
1 Digital input
2 Analogue input
3 Output
6 CAN-Bus
12 Change-over contact
14 Axis X
15 Axis Y
16 Pinning system
18 System monitoring
19 Jib
20 Main hoist
21 Auxiliary hoist
22 Derricking
23 Telescoping
24 Slewing
Error Codes
1.3 Possible Errors
Error No. Fig. Error Error source

Digital Input
2 Wire break Digital Output
Digital Input
3 Short circuit to Vcc
Digital Output
Digital Input
4 Short circuit to ground
Digital Output
Below minimum Analogue input
7
threshold value
Above maximum Analogue input
8
threshold value
ADC value does not suit Digital Input
9
digital level
10 Undefined status Digital Input
11 Initialising software System error
13 Software function call System error

Joystick
14 Logic
Rocker switch
15 PWM-signal error Digital Input
Error Codes
2 List of Components
2.1 Digital Inputs (Group Number 1)
2.1.1 Digital Inputs of ESX 0..2
Device number
1 2 3
Index
1 IN3504 NC S3530
2 A1101/7 NC NC
3 A1201/7 NC S1102
4 IN3503 NC S3702/24
5 A1101/3 S2111P S3702/44
6 A1101/4 S2112P NC
7 A1201/3 S2209N NC
8 A1201/4 S2210N NC
9 S1101P NC J3502-16
10 S1102P NC S1202
11 S1201P NC S2102
12 S1202P NC S2103
13 S2101P NC S2404
14 S2102P NC S2304
15 NC NC S3710
16 NC NC J3501-16
Error Codes
2.1.2 Outputs of ESX 0..2
Device number
1 2 3
Index
1 OUT1100 OUT2300 B3401
2 OUT1200 Y2305 J3501-13
3 OUT2100 Y2105 J3502-13
4 OUT2110 Y2115 OUT3401
5 Y3403 Y2306 B3702
6 Y3501 Y2304 H2404
7 Y1104 Y2307 H1102
8 Y1105 Y2104 H1202
9 Y1204 K2112 NC
10 Y1205 M0101 NC
11 K3510 Y2134 NC
12 K3511 Y2133 H3501
13 K1101 K2301 H2304
14 K1102 K2302 H2102
15 K1201 K2101 H2112
16 K1202 K2102 NC
17 NC K2111 H3502
18 U0-VCC-Perm U1-VCC-Perm U2-VCC-Perm

Error Codes
2.1.3 Analogue Inputs of ESX 0..2
Device number
1 2 3
Index
1 IN3503a IN2302P S0106/1
2 IN2401 IN2103P S0106/7
3 IN3709 S0221Q S3401/1
4 OUT0201 S0243T S3401/7
5 OUT0202 IN2205 IN2301
6 IN3501P IN2206 NC
ESX ESX ESX
7
identity identity identity
ESX ESX ESX
8
identity identity identity
2.2 IO - card
2.2.1 Analogue Inputs of IO - card 0..1

Device number
9 10
Index
1 NC NC
2 NC NC
3 NC NC
4 IN2201P NC
5 NC NC
6 NC NC
7 NC NC
8 NC NC
Error Codes
2.2.2 Digital Inputs and Outputs of IO - card 0..1

Device number
9 10
I O
Index
I I
1 S2323 S3709N
I I
2 A2320/7 S3710N
I
3 A2320/5 NC
I
4 S0102P NC
5 NC NC
I
6 S2303P NC
I
7 NC S3706N
I
8 NC S3708N
O I
9 NC S2110N
O I
10 NC S2111N
O I
11 NC S2112N
O I
12 NC S2113N
I I
13 NC S2114N
I I
14 NC S2115N
I
15 NC S2116N
I
16 NC S2117N
O O
17 Y3401 Y2130
O O
18 Y3402 Y2131
O
19 Y2401 NC
O
20 Y2402 NC
O
21 Y2201 NC
O
22 Y2202 NC
23 NC NC
24 NC NC
Error Codes
2.3 Joystick Errors

Device Group Index Error Description
No. Fig. No. Fig. No. Fig.
The CAN bus connection to the left joystick
17 6 0 0 was lost.
Electric error.Both axis falled out, exchange
17 18 0 1 left joystick.
17 12 0 14 Both contacts switched (rocker switch)
Redundant system falled out. Joystick can

17 14 0 1 further use. Is the error activ after restart the
system, exchange joystick.
Axis is falled out. Is the error activ after restart
17 14 0 2 the system, exchange joystick.
The CAN bus connection to the right joystick
18 6 0 0 was lost
Electric error.Both axis falled out, exchange
18 18 0 1 right joystick.
18 12 0 14 Both contacts switched (rocker switch)

Error Codes
2.4 ECOS Errors (Device Number 25)
2.4.1 Change-over Contact Group (Group Number 12)

No. Fig. No. Fig. No. Fig.
Both directional contacts switched
25 12 0 14
(Tilt cab)
Both directional contacts switched

25 12 1 14 (engine speed raise/lowering)
2.4.2 Pinning System Group (Group Number 16)

No. Fig.
Error of the EKS4 length sensor for the telescoping cylinder length
- The redundant length control (comparison of ECOS length with
25 16 0 0
EKS4 length) is no longer operating, resulting in losses in the
system safety of the telescoping system
Error in comparing the ECOS length with the EKS4 length
- The difference in the two lengths has exceeded the tolerance
threshold (set by service software), i.e. one of the two length
sensors is emitting an invalid value
25 16 1 4 - Semi- and fully automatic operation are no longer functioning;
the locking system can only be operated in emergency operation
- During emergency operation the current length of the ECOS
length sensor and the EKS4 length sensor are displayed; a
decision has to be made as to which length information is correct
Error in controlling the telescoping cylinder movement
- It was established that the current direction of movement of the
telescoping cylinder contradicts the telescoping system’s
25 16 1 5 operating status (e.g. retracting direction of movement and
extending operating status)
- Semi- and fully automatic operation are no longer functioning;
Error in controlling the telescope status
- The telescopic status is inconclusive in itself (e.g. more than one
telescope section unlocked)
25 16 2 1 - All the functions of the telescoping system are blocked; a valid
telescope status must first be input or a change made to
emergency operation
- The position of the telescoping cylinder in connection with the
telescope status contradicts the locking system’s operating status
25 16 2 2 (is only evaluated in TLSL operating status)
- All the functions of the telescoping system are blocked; a valid
emergency operation
- The current telescopic status contradicts the locking system’s
current operating status (e.g. TLSU operating status, however
25 16 2 3 according to telescope status no telescope section is unlocked)
emergency operation
Error Codes

- The proximity switches’ signals for detecting the position of the
telescoping cylinder (S2116N, S2117N, S3709N, S3710N)
contradict the locking system’s current operating status (e.g.
25 16 2 4 TLSU operating status, however none of the proximity switches
has switched)
emergency operation
- The proximity switches’ signals for detecting the position of the
telescoping cylinder (S2116N, S2117N, S3709N, S3710N)
contradict the telescope status and the position of the telescope
cylinder (this error can only occur in operating status TUSL;
25 16 2 5 proximity switches have switched but the telescope cylinder is
not within a foot section)
emergency operation
Error in detecting the locking status
- The evaluation of the proximity switches’ signals for detecting
the locking status (S2110N – S2115N) produces an invalid status
25 16 3 n the locking system can only be operated in emergency operation
- The error number 'n' indicates which proximity switches (S2110N
- S2115N) were switched at the time the error occurred
- See explanations regarding this in chapter 2.4.2.1
Error in the unlocking mechanism
- The wrong pins were released during an unlocking request (e.g.
request for the telescoping cylinder to be unlocked, but the
telescope section was unlocked)
25 16 4 0 - Presumed error: valve Y2130 for switching over unlocking
between telescoping cylinder and telescope section is sticking.
Error of proximity switches S3709N and S3710N
- Both proximity switches S2116N and S2117N have switched, but
neither of the proximity switches S3709N and S3710N have
switched.
- Possible mechanical error: the telescoping cylinder moved to the
right so that the proximity switches on the left-hand side of the
25 16 5 0 cylinder have lost contact to the trigger plates.
- There might be function restrictions of the telescoping system.
The recognition of the foot sections might fail. It may be that the
telescoping cylinder cannot be locked to a telescope section any
more. In this case the telescoping system can only be operated in
emergency operation.
Error of proximity switches S2116N and S2117N
- Both proximity switches S3709N and S3710N have switched, but
neither of the proximity switches S2116N and S2117N have
switched.
- Possible mechanical error: the telescoping cylinder moved to the
left so that the proximity switches on the right-hand side of the
25 16 5 1 cylinder have lost contact to the trigger plates.
- There might be function restrictions of the telescoping system.
The recognition of the foot sections might fail. It may be that the
telescoping cylinder cannot be locked to a telescope section any
more. In this case the telescoping system can only be operated in
emergency operation.
Error Codes
Error of the proximity switch S2116N, S2117N, S3709N or S3710N

- the error code number 'n' determines the respective proximity
switch to which the error message relates:
n = 0 → S2116N
n = 1 → S2117N
25 16 6 n n = 2 → S3709N
n = 3 → S3710N
- the proximity switch remains switched all the time although the
telescoping cylinder is not within a foot section of a telescope
section
2.4.2.1 Explanations regarding Error Message 25.16.3.n

Error message 25.16.3.n (device = ECOS, group = locking system) denotes an error during the
detection of the current locking status. The evaluation of the signals of proximity switches S2110N to
S2115N produces an invalid condition. The error number of this error message (designated here by
'n') reflects the switched condition of these proximity switches at the time the error occurred.
Determining the switched conditions of the proximity switches from the error number 'n':
The proximity switches have various weightings, which are as follows:
S2114N (tele-cyl. lock. left) → Weighting = 1

S2115N (tele-cyl. lock. right) → Weighting = 2
S2112N (tele-cyl. unlock. left) → Weighting = 4
S2113N (tele-cyl. unlock. right) → Weighting = 8
S2111N (boom section locked) → Weighting = 16
S2110N (boom section unlocked) → Weighting = 32
In order to now determine the proximity switches’ switched conditions from the error number 'n',
the error number 'n' is split up into the sum of the proximity switches’ weightings. If the sum
includes a weighting, this means that the proximity switch(es) belonging to this weighting
was/were switched at the time the error occurred. All proximity switches, the weightings of
which are not included in the sum, were not switched.
Example:
Error Message = 25.16.3.33
→ Error number n = 33
→ 33 = 32 + 1, the error number n = 33 includes weightings 32 and 1
→ at the time the error occurred only proximity switches S2110N and S2114N were switched.
Error Codes
2.4.3 System Monitoring Group (Group Number 18)
Valid for devices No. 1 to 3 or No. 9 to 10
bis bis

Error in the control system’s start phase
1..3 18 0 1 • The earth connection to the housing of the relevant ESX is not OK
• The housing’s earthing should be checked.
1..3 18 0 2 • One of the outputs of the relevant ESX has a connection to the
supply voltage.
• The initiating current of the output VCC perm. is greater than 3
1..3 18 0 4 amperes.
• A component at the Vcc perm. connection is causing a short circuit
Operating error
• The total of all of the VCC perm. output current was greater than
1..3 18 0 6 10 amperes.
• A component at the Vcc perm. connection is causing a short circuit
Operating error
1..3 18 0 7 • The total of all the output currents was greater than 28 amperes.
Operating error
• The 8.5V output voltage is outside the tolerance.
1..3 18 0 8 • A component at the 8.5V connection is causing a short circuit, or
the control system is defective.
Operating error
1..3 18 0 9 • Slave has detected a failure of the CAN masters.
• The CAN bus connection should be checked.
Operating error
1..3 18 0 10 • The control system’s output drivers are not supplied with voltage.
• Check fuses and supply voltage.
Error during access to the EEProm
9..10 18 1 0 • Board is to be replaced, if error message occurs with increased
frequency
No voltage supply via plug X9.1 of IO board
9..10 18 1 1 • Check wiring to IO board and also fuse on the IO board
No voltage supply via plug X9.2 of IO board
9..10 18 1 2 • Check wiring to IO board and also fuse on the IO board
Error Codes

No. Fig. No. Fig.
Error on the CAN bus 4 between ESX2 and stand alone
3 18 194 7 device at send a message.

3 18 195 8 device at initialization of the CAN bus.
The ESX 2 has receive a message with a wrong ID on the

3 18 196 5 CAN bus 4.

3 18 209 5 device at initialization of the CAN bus.
The ESX 2 has receive a message with a wrong ID on the

3 18 210 5 CAN bus 4.
Error Codes
2.4.4 Main Hoist Group (Group Number 20)

No. Fig. No. Fig.
Recognize pressure LS (load sensing) for direction of
25 20 2 0 movement positiv and negative.
In the movement positiv became a pressure LS (load

25 20 2 1 sensimg) for direction of movement negative.
In the movement negative became a pressure LS (load

25 20 2 2 sensimg) for direction of movement positiv.
In a state of STOP became a pressure LS (load sensing) for

25 20 2 3 direction of movement positiv.

25 20 2 4 direction of movement negative.
2.4.5 Auxiliary Hoist Group (Group Number 21)

No. Fig. No. Fig.




Error Codes
2.4.6 Derricking Group (Group Number 22)

No. Fig. No. Fig.




2.4.7 Telescoping Group (Group Number 23)

No. Fig. No. Fig.




2.4.8 Slewing Group (Group Number 24)

No. Fig. No. Fig.
The oel current to the slewing motor is 0 and the pressure on
25 24 2 0 the slewing valve is bigger than 20 bar.
Error Codes
2.4.9 Can-Bus Error

No. Fig. No Fig.
The CAN bus connection from ESX 2 to ESX 0 was lost
within the process phase
1 6 0 0 - The superstructure can no longer be operated from the cab
The handset emergency operation is to be used to de-rig
the crane
within the configuration phase
the crane
Error within the configuration phase:
ESX 0 is a control system from another type of crane
- The connection to ESX 0 is lost
the crane
ESX 0 has the wrong version of software
the crane
ESX 0 has a serial number, however the EEPROM data is not
valid
1 6 1 3 - The connection to ESX 0 is lost
- The superstructure can no longer be operated from the cab
the crane
ESX 0 has an incorrect serial number
the crane
during the transition of ESX 0 to the STOP mode
the crane
The configuration data from ESX 0 could not be fully
received.
the crane
during the transition from the configuration phase to the
process phase
the crane
Error Codes

No. Fig. No Fig.
- The sensors and valves connected to this ESX are no
2 6 0 0 longer available to the ECOS
- Functional restrictions are imposed on the drive units, the
sensors or valves of which are connected to this ESX
2 6 1 1 - The sensors and valves connected to this ESX are no
longer available to the ECOS
valid
received
Error Codes

process phase
Error Codes

No. Fig. No Fig.
valid
received
Error Codes

process phase
Error Codes

No. Fig. No. Fig.
The CAN bus connection from ESX 0 to IO 0 was lost within
the process phase
- The sensors and valves connected to this IO are no longer
9 6 0 0 available to the ECOS
sensors or valves of which are connected to this IO
the configuration phase
The CAN bus connection from ESX 0 to IO 0 was lost during
the transition from the configuration phase to the process
phase
9 6 2 0 - The sensors and valves connected to this IO are no longer
available to the ECOS

No. Fig. No. Fig.
the process phase
the configuration phase
The CAN bus connection from ESX 0 to IO 1 was lost during
the transition from the configuration phase to the process
phase
10 6 2 0 - The sensors and valves connected to this IO are no longer
available to the ECOS
Error Codes

No. Fig. No. Fig.
The CAN bus connection from ESX 2 and ESX 0 to the EKS
19 6 0 0 was lost
The CAN bus connection from ESX 1 to the precision length

20 6 0 0 sensor was lost
The CAN bus connection from the stand alone device to the
24 6 0 0 inclination sensor was lost
The CAN bus connection from ESX 2 to the joystick on the

17 6 0 0 left side was lost
The CAN bus connection from ESX 2 to the joystick on the

18 6 0 0 right side was lost
Error Codes
2.5 Device Stand Alone (Error CAN bus)

No. Fig. No. Fig.
43 6 193 1 Cycle time of CAN messages between stand alone device

and ESX2 became about the limit.
The ESX 2 has no data from the stand alone device receive
43 6 193 2 inside a time from 5 seconds.
43 6 197 3 ESX2 has receive a wrong ID from the stand alone device.
43 6 197 4 The data length from the received message was not correct.
The CRC value from the received message was not correct..
43 6 197 5 Error on the CAN bus. Possible EMC pikes.
The ESX 2 has a message from the stand alone device not
43 6 197 6 received.
43 6 211 1 ESX2 has receive a wrong ID from the stand alone device.
43 6 211 2 The data length from the received message was not correct.
The CRC value from the received message was not correct..
43 6 211 3 Error on the CAN bus. Possible EMC pikes.
The ESX 2 has a message from the stand alone device not
43 6 211 4 received.
Error Codes
3 Assignment of the ESX

Pin Designation Pin Designation
27 1stCAN bus, dominant higher, W+ 38 Digital speed input 9
26 1stCAN bus, dominant lower, W- 16 Digital speed input 10
33 2ndCAN bus, dominant lower, W- 39 Digital speed input 11
53 2ndCAN bus, dominant higher, W+ 17 Digital speed input 12
23 8.5 V output 40 Digital speed input 13
6 Analogue input 1 18 Digital speed input 14
30 Analogue input 4 46 Digital/PWM output 1, (4 A with current measurement)
42 Digital/PWM output 13, (4 A) 61 Digital/PWM output 6, (4 A)
21 Digital/PWM output 16, (4 A) 24 Digital/PWM output 9, (2,5 A)
45 NC 3 Digital/PWM output 12, (2,5 A)
11 NC 1 Ground, analogue
50 NC 55 Ground Electrics, digital
51 NC 65 Ground for Babyboard 1
52 NC 66 Ground for Babyboard 1
10 NC 67 NC
28 D+ input 68 NC
34 Digital speed input 1 4 Serial interface, RxD
12 Digital speed input 2 5 Serial interface, TxD
35 Digital speed input 3 56 Voltage supply 12 V (24 V), UB
15 Digital speed input 8 54 Voltage supply 12 V (24 V), UE

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System Description TMS 9000E
Error Codes

ECOS Error Codes TMS 9000E

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XXX – XXX – XXX – XXX

1.1 List of Devices

Device-No. Device Fig. Device-No. Device Fig.

2 ESX 1 20 Position length sensor

17 Joystick left 43 Stand Alone

1.2 List of Groups

Group -No. Group Fig. Notes

1.3 Possible Errors

Error No. Fig. Error Error source

10 Undefined status Digital Input

11 Initialising software System error

13 Software function call System error

5 A1101/3 S2111P S3702/44

2.1.2 Outputs of ESX 0..2

1 OUT1100 OUT2300 B3401

2 OUT1200 Y2305 J3501-13

3 OUT2100 Y2105 J3502-13

4 OUT2110 Y2115 OUT3401

5 Y3403 Y2306 B3702

6 Y3501 Y2304 H2404

7 Y1104 Y2307 H1102

8 Y1105 Y2104 H1202

12 K3511 Y2133 H3501

13 K1101 K2301 H2304

14 K1102 K2302 H2102

15 K1201 K2101 H2112

18 U0-VCC-Perm U1-VCC-Perm U2-VCC-Perm

2.1.3 Analogue Inputs of ESX 0..2

2 IN2401 IN2103P S0106/7

3 IN3709 S0221Q S3401/1

4 OUT0201 S0243T S3401/7

5 OUT0202 IN2205 IN2301

2.2.1 Analogue Inputs of IO - card 0..1

2.2.2 Digital Inputs and Outputs of IO - card 0..1

2.3 Joystick Errors

17 12 0 14 Both contacts switched (rocker switch)

Redundant system falled out. Joystick can

18 12 0 14 Both contacts switched (rocker switch)

Redundant system falled out. Joystick can

2.4 ECOS Errors (Device Number 25)

2.4.1 Change-over Contact Group (Group Number 12)

Device Group Index Error Description

Both directional contacts switched

2.4.2 Pinning System Group (Group Number 16)

Device Group Index Error Description

Error in controlling the telescope status

Error of the proximity switch S2116N, S2117N, S3709N or S3710N

2.4.2.1 Explanations regarding Error Message 25.16.3.n

The proximity switches have various weightings, which are as follows:

S2114N (tele-cyl. lock. left) → Weighting = 1

2.4.3 System Monitoring Group (Group Number 18)

Valid for devices No. 1 to 3 or No. 9 to 10

Device Group Index Error Description

Device Group Index Error Description

Error on the CAN bus 4 between ESX2 and stand alone

The ESX 2 has receive a message with a wrong ID on the

Error on the CAN bus 4 between ESX2 and stand alone

The ESX 2 has receive a message with a wrong ID on the

2.4.4 Main Hoist Group (Group Number 20)

Device Group Index Error Description

In the movement positiv became a pressure LS (load

In the movement negative became a pressure LS (load

In a state of STOP became a pressure LS (load sensing) for