ECOS System Overview

GMK-4.
1 Generation 2 ECOS
ECOS System Overview
ECOS Overview
This document pertains to ECOS Generation 2 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 Generation 2 ECOS System Overview
ECOS Overview

ECOS Overview

ECOS Overview
RT 9150

ECOS Overview

ECOS Overview

ECOS Overview

ECOS Overview

ECOS Overview
As ECOS uses ESX modules, sensors and displays etc.

networked over several CAN bus circuits, it is important to treat
each as an individual circuit when troubleshooting.

CANBUS Overview

ESX Module Overview

ESX Module Overview

ESX Module Layout
Unlike “Generation 1” machines, the layout and

functions of the ESX modules on “Generation 2”
machines is dependent on the model. A model
specific ESX layout and functionality will be
discussed later in this presentation.
The Master module on “Generation 2” machines
is always the one located in the superstructure
cab.
The example shown here is ESX-2 and it’s
functions are:
Crane Cab Control
Model 5130-1 Example Control Levers (Joysticks)
Crane Control Display

ESX Module Layout
ESX-0 is the superstructure master of ESX-1,

I/O-3 and I/O-4.
functions are:
Main Hoist System
Auxiliary Hoist System
Slewing System
Telescope System
Derricking System
Counterweight System
Turntable Lock System
Cab Tilt System
Model 5130-1 Example

ESX Module Layout
ESX-1 is located on the superstructure and is a

slave to ESX-0.
functions are:
Slewing System
Telescope System
Derricking System
Counterweight System
Model 5130-1 Example

ESX Module Details

ESX Module Functionality
The diagram to the left shows the

possible ESX module connections:
Eighteen digital outputs (valves etc.)
Sixteen digital inputs (switches etc.)
Eight analogue inputs (sensors etc.)
Five 24V Voltage Supplies UB
24V Voltage Module Supply UE
24V Voltage Ignition Supply D+
VCC Perm 24V Output
8.5V VCC Output
2 CANBUS Connections (Spur-line)
Primary CANBUS Interface
Secondary CANBUS interface

ESX Module Functionality

Assignment of the ESX
Pin Designation Pin Designation

27 1st CAN bus, dominant higher, W+ 38 Digital speed input 9
26 1st CAN bus, dominant lower, W- 16 Digital speed input 10
33 2nd CAN bus, dominant lower, W- 39 Digital speed input 11
53 2nd CAN 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

I/O Board & Module Overview
Type-1 Type-2

Type-1 I/O Board Details
The I/O boards are all identical and are given a unique address for specific tasks by
setting of the address code rotary switch which is located on the top right hand side of
each I/O board. The switch has sixteen positions and can be set from 1 to F.
Immediately to the right of the code switch are two pins which if bridged allow the boards
flash memory to be re-flashed via the RS 232 interface. It is not a normal field issue to re-
flash I/O boards.
The board also has 2 CANBUS connections connected in series. (Ring Structure)


LED Color Status Meaning

V1 Yellow Off Board in hardware reset
V1 Yellow On uC initializing ended
V113 V1 Yellow Flashing Main program running (√ *)
V2 Red Off No timeout
V2 Red On Timeout
V3 Green On Initializing or configuration phase (√ )
V3 Green Off Process or timeout phase
V119 Green Off Vcc defective (hardware)
V119 Green On Vcc OK (hardware) (√ )
V113 Yellow Off CAN bus recessive (hardware) (√ ** )
V113 Yellow On CAN bus dominate (hardware) (√ **)
Basic board troubleshooting via LED display

V1 V2 V3 V119
(√ * ) LED will blink
(√ ) LED on
(√ ** ) LED will flicker to show transmission

Type-1 I/O Board Layout
I/O board locations and types will vary

depending on the model type. Specific
board locations and types will be
discussed later in this presentation.
Model 5130-1 S/S Example

Type-2 I/O Modules
The Type-2 GVIOM modules are all GVIOM

identical and are given a unique
address for specific tasks by the wiring GroVe Input Output Module
of the connection plug. Plug connection
pins 38 and 39 determine the modules
functionality.
These modules contain operation

software which is flash rom and flashed
via the ESX Flasher program. GVIOM
software is not model specific except for
TMS9000E stand only module.
Unlike Type-1 I/O boards, this style I/O

has only 1 CANBUS connection.

Type-2 I/O Modules
Female Plug

Type-2 I/O Modules
Male Plug
1 14
15 28
29 42

Type-2 I/O Module Details
ID_LOW (AGND)
ID_TRISTATE (leave unconnected)
ID_HIGH (+UE)
GVIOM Specifications:
Power Supply 18...32V max.16A
IIN IIN : 0...24mA +UB 24V-power supply output-driver
UIN UIN: 0...32V +UE 24V-power supply main board
DO 2A (high-side switch) AGND Analog ground (keep clean for internal measurement
GND Ground
UIN_DO Voltage-In/Digital-Out (1-16 Input/Output 17-24 Input)
IIN Current-In

Telescope Cylinder Modules

Relay Boards
A Relay Board is used to allow single ESX proportional

outputs to control directional solenoids for primary crane
functions. Also these boards contain the ESX ID
resistors, CAN-bus termination resistors and power
supply protection fuses.

Relay Boards

Relay Boards

Joysticks / 1st Version
Two X/Y axis joysticks are installed and are identified as J3501
(left) and J3502 (right). Both have multiple switches and a
vibrator integrated into the palm grip for deadman, horn, all-wheel
steering and HDRI functions.
The control X/Y axis covers a mA current output span of 4 – 12 –
20 mA with a +/- bias from the neutral position of 12 mA. Meaning
that when a maximum + selection is made the output current will
rise from 12 – 20 mA; subsequently a maximum – selection gives
a falling output current from 12 – 4 mA. These command values
are routed to ESX3 and transmitted via CAN bus to the
appropriate module for conversion to a PWM output with current
measurement to drive proportional valves.
The joystick houses four internal contact switches. When the +/-
X/Y axis is operated a single switch is closed for each +/- axis to
provide 24V directional signals to ESX3. These direction signals
are then transmitted via CAN bus to the appropriate module for
conversion to a digital output current to energize the respective
direction / control valves.
4075 - Example


4075 - Example

Joysticks / Coded Version
Rocker Switch
Horn Button
Switch
HDRI
Deadman
Switch

The differentiation of the installation site is made

by means of the identifier (CAN bus address) of
the control levers, which is adjusted via a rotary
switch on the underside of the control lever.
Code
Selector






ECOS Component Locations
Model Comparison

Model 3055

Model 4075

Model 4080

Model 4100

Model 5130-1

Model 5220

Model 7450

Function Overviews
Model Comparison

Model 3055
Hoist Animation

Model 4075

Model 4100

Model 5130-1

Model 7450


ECOS System Overview

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GMK-4.

This document pertains to ECOS Generation 2 equipped GMK cranes. The

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

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

As ECOS uses ESX modules, sensors and displays etc.

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Unlike “Generation 1” machines, the layout and

Grove Manitowoc National Crane Potain

ESX-0 is the superstructure master of ESX-1,

Grove Manitowoc National Crane Potain

ESX-1 is located on the superstructure and is a

Model 5130-1 Example

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

The diagram to the left shows the

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Pin Designation Pin Designation

26 1st CAN bus, dominant lower, W- 16 Digital speed input 10

33 2nd CAN bus, dominant lower, W- 39 Digital speed input 11

53 2nd CAN 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

29 Analogue input 2 41 Digital speed input 15

7 Analogue input 3 19 Digital speed input 16

30 Analogue input 4 46 Digital/PWM output 1, (4 A with current measurement)

8 Analogue input 5 47 Digital/PWM output 2, (4 A with current measurement)

31 Analogue input 6 48 Digital/PWM output 3, (4 A with current measurement)

9 Analogue input 7 49 Digital/PWM output 4, (4 A with current measurement)

32 Analogue input 8 64 Digital/PWM output 5, (4 A with current measurement)

42 Digital/PWM output 13, (4 A) 61 Digital/PWM output 6, (4 A)

20 Digital/PWM output 14, (4 A) 62 Digital/PWM output 7, (4 A)

43 Digital/PWM output 15, (4 A) 63 Digital/PWM output 8, (4 A)

21 Digital/PWM output 16, (4 A) 24 Digital/PWM output 9, (2.5 A)

44 Digital/PWM output 17, (4 A) 2 Digital/PWM output 10, (2.5 A)

22 Digital/PWM output 18, (4 A) 25 Digital/PWM output 11, (2.5 A)

45 NC 3 Digital/PWM output 12, (2.5 A)

50 NC 55 Ground electrics, digital

51 NC 65 Ground for Babyboard 1

52 NC 66 Ground for Babyboard 1

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

13 Digital speed input 4 57 Voltage supply 12 V (24 V), UB

36 Digital speed input 5 58 Voltage supply 12 V (24 V), UB

14 Digital speed input 6 59 Voltage supply 12 V (24 V), UB

37 Digital speed input 7 60 Voltage supply 12 V (24 V), UB

15 Digital speed input 8 54 Voltage supply 12 V (24 V), UE

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

Grove Manitowoc National Crane Potain

LED Color Status Meaning

Basic board troubleshooting via LED display