Gen 1 Overview & Model Comparison

GMK Gen.
1 ECOS
Overview
This document pertains to ECOS equipped GMK cranes. The scope of this material
serves to inform the individual of the variations of control software / hardware of the
ECOS computer systems utilized in current and past production models. With regards
to the ECOS system it should be noted that the system is a stand alone control
system and dependant on model the control system associated with carrier functions
can vary significantly.
Also note there is software / hardware control elements utilized by Mercedes,

Cummins, Allison, ZF, etc some of which directly / indirectly interface with the ECOS
operating system.
Grove Manitowoc National Crane Potain

1 ECOS Preview
Generation 1 ECOS:

2 ECOS Preview
Generation 1 ECOS:

3 ECOS Preview
Generation 1 ECOS:

4 ECOS Preview
1 Generation-1 Model Comparison
(PVR & RVR Boards are no longer used.)

All generation 1 machines have the same basic control architecture
CAN - Bus Engine

Management
Main Hoist Telescoping Slewing

Aux. Hoist Derricking Aux. Drives
Luffing

Common components across model lines

Typical relay panel installation (5100 shown)
1. 20 Amp Relays 6. 50 Amp High Capacity Relays

2. Bosch Micro Relays 7. ECOS Resistor Boards
3. Main Fuse Panel 8. A3505 GLR Translator Unit
4. Telemecanique Relays 9. ECOS EST Identity Resistors / PTJ
5. Telemecanique Time Relays Control Resistor

Typical EST Module installation
All ECOS control modules (EST’s) contain the same software. The modules are
numbered 0 to 2. Unit 0 is the most important as it acts as the master control unit, the
recorded crane data (serial number, hours, error logs, etc.) are logged in this unit.
Since all control modules contain identical software, every module may replace the
others. In case of emergency operation it must merely be guaranteed that unit 0 is
activated since the control levers are connected here.

EST Module functionality
The ECOS units called EST’s each have two replaceable

EPROMS. One EPROM is a low byte and the other is a high
byte.
With the unit removed from the crane and the cover then
removed, you can see both EPROMS. They are normally
retained with a cable tie.
Both chips are beside each other with the high byte chip being
slightly higher on the board.
When replacing chips, ensure that the chip orientation is

correct by locating the chip in the board with the chip indent
towards you.

EST Module functionality
When the starting procedure is triggered (ignition on
or engine start), each control module will receive
information on which primary functions it must carry
out. Primary control functions are allocated as:
Unit 0 – Main Hoist, Auxiliary Hoist, Control Levers
Unit 1 – Derricking, Telescoping
Unit 2 – Slewing, Auxiliary Drives
It should be noted that in addition to the primary functions, depending on the model,
an individual control module may have other functions allocated to it (e.g. speed
operation, jib operations, etc.)
Also at start up Unit 0 will check and update units 1 and 2 to ensure all modules are
operating with the same version software and crane serial number. If the the software
versions are the same then the various Imin/Imax, speed settings, pinning
parameters, adjustment values will be updated. Should the software version or serial
number in units 1 and 2 be different than unit 0, then the relevant module functions
will be suspended and corresponding error messages displayed.

Typical EST Module ID Resistor Block installation
The first task when the control modules are started consist of recognizing to which
adaptor plug it is connected since it is via the adaptor plug that the sensors and
actuators are connected to the control module. This task is solved by means of a
resistance ID connected to a current output.
When the control modules recognize their resistance ID they will signal their
readiness to the other modules via CAN-Bus.

EST Module ID Resistor Block functionality
On start up the EST modules output 10 mA from

pin 10 to verify the identifier resistor to which it is
connected.
According to Ohm’s Law, U = R x I, a voltage drop
occurs across the resistance which is measured by
the control unit.
If the EST module recognizes the resistance connection, the module than reduces the
current output on pin 10 from 10 mA to 4 mA and commences its program. If the EST
module can not recognize a resistance connection it switches the current output on pin
10 from 10mA to 20 mA and suspends it’s operation until the next start cycle.
These current draws cause a voltage drop which may be measured:

Connection recognized: voltage at the resistance = 0.4 – 1.2 volts
Connection not recognized: voltage at the resistance = 2.0 – 8.5 volts
Note: The above are examples, these voltage drops should be measured to be certain.

Switched Inputs
Part of design criteria for the ECOS system is that interconnected components are
continuously monitored for errors. Digital inputs from proximity switches are all
connected to ECOS via resistor boards.
The ECOS modules continuously emit a reference voltage (7.2 volts typically) through
the switched circuits, which is pulled down to a threshold level by resistor boards.
These threshold levels are then accepted by ECOS as a open or closed switch due to
software program parameters.
When a digital switch is open, the reference voltage (7.2 volts) is pulled down via the
resistor board to a threshold level of approximately 2.3 volts and is accepted by
ECOS as an open switch.
When a digital switch is closed, the reference voltage (7.2 volts) is flooded with a
switched voltage of 24 volts. Due to the additional voltage the resistor board is unable
to hold the threshold level of approximately 2.3 volts and the voltage level rises to
approximately 4.6 volts and is accepted by ECOS as a closed switch.
Should there be any circuit malfunction such as short to ground, short to battery or
cable break, these would be flagged as errors by ECOS due to the error induced
voltage levels being outside the program parameters.

Typical Resistor Board installation all models
Note: Boards for counterweight, luffing jib, etc. may be used, see machine specific schematics for correct detail.

Resistor board functionality
The resistors have the following values:

R1 – 3.16k Ω
R2 – 20.5k Ω
R3 – 1.5k Ω
Approximate reference voltage between
ECOS and the resistor board is 7.2 volts.
Approximate voltage readings when

checking terminal 1a on resistor board:
0 to 1V = Short to Ground
1.1 to 3.3V = Switch Open (2.3 typically)
3.3 to 6.3V = Switch Closed (4.6 typically)
6.3 to 8.5V = Cable Break (7.2 typically)
8.5 to 24V Short to Battery Voltage

2.3v

4.6v

7.2v
With function activated, you

will see approx. 3.1 VDC at
terminal 1a

Crane Controls
Joystick Module
Two joysticks with x / y control axis are
installed, both joysticks have the same control
characteristics.
The control output span = approximately 0.8V
(4mA) to 4V (20mA) for each function to ECOS
unit 0.
Two safety zero contacts (one output per axis)
are used in each joystick for relay control to
interlock the direction control solenoids. These
must close prior to the direction contacts.
Four direction control contacts, one output for
each function, are used in each joystick for
control status to ECOS unit 0.

Crane Controls

Crane Controls

Crane Controls

EST Pin Out
Numerical order
Pin:
1. analog ground
2. digital output #1; 0.5A
4. com-port RXD
5. com-port TXD
6. analog current input #8; 4-20mA
10. analog current output; 4-20mA
11. analog input #1; 0-8.5 V
12. digital input #4; RPM input
14. digital input #18

23. output 8.5 Vcc
26. CAN-Bus Lo; W-
27. CAN-Bus Hi; W+
28. ignition D+
33. analog input #1; 0-8.5 V

46. digital output PWM #1; 4A
54. UB supply +24 V
55. analog ground
56. UB supply +24 V
57. UB supply +24 V

58. UB supply +24 V
59. UE supply +24 V
60. UE supply +24 V
61. digital output #1; 4A

Basics of Function Operation
To begin operation the ECOS system

requires three basic inputs from the
operator controlled joystick. These
inputs consist of a function release
signal, a directional signal and a
command value in mA.
The time relay interface between the
ECOS unit and the direction control
solenoids is installed as a watchdog
safety feature to disconnect the
direction control solenoids from the
system once the operator has
released the joystick and the pre-set
time has elasped.

CONTROL STRUCTURE
5100 5200
6300

5100 - CAN HUB

5200 - CAN HUB

6300 - CAN HUB

5100 - POWER SUPPLY

5200 - POWER SUPPLY

6300 - POWER SUPPLY

5100 - CONTROLS

5200 - CONTROLS

6300 - CONTROLS

5100 SLEW CONTROL

5100 SLEW CONTROL

5100 SLEW CONTROL

5100 SLEW CONTROL

5100 SLEW CONTROL

5100 SLEW CONTROL

5100 SLEW CONTROL

5100 SLEW CONTROL

5100 SLEW CONTROL

6300 SLEW CONTROL WLOAD CENTERING

6300 SLEW CONTROL W/LOAD CENTERING


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GMK Gen.

Also note there is software / hardware control elements utilized by Mercedes,

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

CAN - Bus Engine

Main Hoist Telescoping Slewing

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

1. 20 Amp Relays 6. 50 Amp High Capacity Relays

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

The ECOS units called EST’s each have two replaceable

When replacing chips, ensure that the chip orientation is

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

On start up the EST modules output 10 mA from

These current draws cause a voltage drop which may be measured:

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

The resistors have the following values:

Approximate voltage readings when

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

With function activated, you

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

2. digital output #1; 0.5A

3. digital output #2; 0.5A

6. analog current input #8; 4-20mA

7. analog current input #6; 4-20mA

8. analog current input #4; 4-20mA

9. analog current input #2; 4-20mA

10. analog current output; 4-20mA

11. analog input #1; 0-8.5 V

12. digital input #4; RPM input

13. digital input #2; RPM input

14. digital input #18

15. digital input #16

16. digital input #14

17. digital input #12

19. digital input #8

20. digital input #6

21. digital input #4

22. digital input #2

23. output 8.5 Vcc

24. digital output #3; 0.5A

25. digital output #4; 0.5A

26. CAN-Bus Lo; W-

27. CAN-Bus Hi; W+

29. analog current input #7; 4-20mA

30. analog current input #5; 4-20mA

31. analog current input #3; 4-20mA

32. analog current input #1; 4-20mA

33. analog input #1; 0-8.5 V

Gen 1 Overview & Model Comparison

Gen 1 Overview & Model Comparison