Customer Support Info N - 01-2009: DEMAG Rope Hoist DR DR-Controller and DPC-Modul (Parallel-IN) and

Customer Support Info No.
01-2009
DEMAG Rope Hoist DR
List of error-codes
DR-Controller and
DPC-Modul (Parallel-IN) and
DSE-10 Pendant
with additional comments Update 2009-01-31
090213-EN Dept.1922 - Product Support

0 Handling the Error-Code-Lists
Errorcodes of control panels (DSE-10, DPC, HBC, DRC-J, DRC-10, DRC-DR) will not be saved in an
error memory, neither in the panel itself nor in the DR controller.
0.1 DR-Controller
Encoding of messages from DR control systems (Display messages):
Message Only one trolley One of two trolleys selected Both trolleys selected
Zur
1 to 99 Message of trolley Message of selected trolley Message of trolley 1
101 to 199 Message of crane Message of crane Message of crane
201 to 299 Not possibel Message of not selected trolley Message of trolley 2
To identify the origin, 100 is added to the error code by the crane control system and 200 by the
control system of the other trolley.
The error codes are entered into the error memory of each control system without this added origin
identification.
Display of "negative" load values after taring: The load display alternates between the load value
and the value 0.00
0.2 Radio Control DRC
A leading 9 will be added to all internal errors of the radio control system DRC
z.B. 950 = Monitoring controller of radio receiver card has detected missing
objects on CAN bus
0.3 DPC- Modul (Parallel-IN)

It is only possible to read the error-codes of the DPC-modul via the internal 7-Segments-Diplay.
Therefore it is necessary to open the housing.
0.4 Pendant Control DSE internal DSE faults
With DSE-10 the internal errorr-codes can be read out after activation
(see manual) in the left upper area of the display (parallel to DR-
errorcode), otherwise (without activation) only via
collective error symbol faults DR-Controller
Warning and error codes of DR control systems
Flash codes of main controller (green LED, operating statuses)
Status Source Flash codes Description Possible malfunction / causes
Normal operation Main controller █ (1x) Normal operation Normal operating status
Emergency operation Main controller █ █ (2x) Limitations for operation of one or both axes Failure of a monitoring function (see error code)
K1/KMS off Main controller █ █ █ (3x) One or both axes completely blocked Failure of a function necessary for operation (see error code)
Crane contactor off Main controller █ █ █ █ (4x) Crane contactor was switched off Serious and/or safety-relevant error (see error code)
K1/KMS off following KS error Main controller █ █ █ █ █ (5x) All contactors off following error of crane contactor Crane contactor control error (see error code)
Flash codes of main controller which take priority over the first 5 flash codes:
Parameter programming Main controller █ █ █ █ █ █ (6x) Parameters need to be programmed or Format/delete necessary or Parameter programming is- Status during parameter programming
being carried out or EEProm defectiv, crane contactor off - Parameter programming necessary as parameter incomplete, not activated,
invalid check sums, etc.
- Format/delete necessary as EEProm may contain data of an older version
Monitoring controller error Main controller █ █ █ █ █ █ █ (7x) Main controller has detected incorrect behaviour of monitoring controller DR control system error (replace control system)
CAN not ok Main controller █ █ █ █ █ █ █ █ (8x) Main controller has detected error of CAN bus - Check Can bus connection ( plug loose / cable defective / ... )
- Other Can bus subscriber not working
- Incorrect setting ( parameters / Dip switches / final resistor / ... )
Flash codes of main controller (red alarm LED) only from hardware version 5
Behaviour Description Possible malfunction / causes
LED flashes for splits of a second CAN bus has short-term fault (individual objects) Interference by switching processes or another EMC source
LED on for some seconds Data exchange via the CAN bus temporarily blocked - Individual SRDO error (safety objects on CAN bus) has occurre
- Start-up of another DR control system
- Poor bus connection
- Massive interference
p by EMC source
LED permanently on - Data exchange via the CAN bus permanently blocked - Error or failure of another DR control system
Flash codes of monitoring controller (blue LED)

Normal operation Mon. controller █ Normal operation Normal operating status
Operation in Debug mode Mon. controller █ █ Monitoring controller working with Debug software DR control system error (replace control system)
Waiting for start Mon. controller █ █ █ Monitoring controller is waiting for synchronising start command from main controller - Jumper for watchdog not fitted or has contact problems
- DR control system error (replace control system)
Waiting for parameter Mon. controller █ █ █ █ Monitoring controller is waiting for parameter from main controller - Jumper for watchdog not fitted or has contact problems
Watchdog or HW error Mon. controller ██████████ etc. Monitoring controller not operational owing to watchdog or HW error DR control system error (replace control system)
Error message Mon. controller █ █ █ █ █ █ etc. Monitoring controller has detected and reported error condition to main controller Status when error detected (see error code)
Horn sequences of DR without error codes

Status Source Flash codes / horn sequences Description Possible malfunction / causes Behaviour of control system
HW error of main controller Main controller ████ ████ █ etc. Hardware error main controller: RAM, check sums, register or stack error DR control system error (replace control system) No function, RESET forces safe status
Watchdog error Main controller ██████████ etc. Watchdog not working, jumper 311 on controller board not fitted - Jumper 311 for watchdog not fitted or has contact problems No function, control system remains at safe status
Sequence "in emergency limit Main controller | | | | | | | | | | | | etc. Emergency limit switch of the hoist unit has been actuated -Emergency limit switch of the hoist unit has been actuated Movement only possible in opposite direction. Movement in the
switch" -Fault in the electrical equipment direction switched off results in a fault.
-Parameter fault or or incorrect configuaration of the DR control (jumper)
Sequence "in rope limit switch" Main controller | | | | | | | | | | | | | | | etc. Rope limit switch has been actuated -Rope limit switch has been actuated Only lowering allowed. Lifting results in a fault.
-Fault in the electrical equipment
-Parameter fault or or incorrect configuaration of the DR control (jumper)
Sequence "in phase-sequence fault Main controller | | | | | | | | | | | | | | | | | | etc. Phase-sequence fault limit switch has been actuated -Phase-sequence fault limit switch has been actuated Neither lifting nor lowering possible.
Panic sequence Main controller | | | | | | | | | | | | | | | | | | | | | etc. Panic function for actuation of the "Check limit switches" button on DRC-10 - "Check limit switches" button on DRC-10 actuated
- Parameter error
Overload Main controller █ █ █ █ █ █ █ etc. Detection of an overload - Actual overload on hook Only lowering is allowed.
- Parameter error
- Mechanical defect of overload protective device
- Load measuring (ZMS) defective
General parameter error Main controller Parameter missing (in internal or external EEprom or in modular hardware in EEprom of the - Parameter error No function, control system remains at safe status
ZMS module) or has impermissible value, detected during start-up - Parameter outside specified limits
███ █ █ █ - Incompatibility between parameters
- Last parameter programming session aborted
Impermissible SW version of main - DR control system error (replace control system) No function, control system remains at safe status
Main controller ███ █ █ █ █ █ █ Software version of main and monitoring controller do not match
controller
Illegible data in EEProm Main controller ███ ███ █ EEProm from version older than V1.10 or contents completely invalid. Format/delete of - EEProm may contain data from older version. Caution! No function, control system remains at safe status
EEProm necessary. - DR control system error (replace control system)
- EEProm missing or has contact problems
- EEProm is full (memory cells may be defective)
Old data in EEProm Main controller ███ ███ █ █ EEProm from version V1.10 to V1.xx . Transfer to current format required. - EEProm contains data of an older version. Caution! No function, control system remains at safe status
Completion message following Main controller ███ ███ █ █ █ █ █ █ Confirmation of control system after Delete/format of EEProm or after transfer of data from - Event due to manipulation by the operator.
manipulation of data in EEProm older version. Control system must be restarted, parameter programming is possible - EEProm was empty before boot-up
Cahnge into the "setup mode" for ID Main controller ███ ███ ███ █ Confirmation of the control after change into the "setup mode" > Event due to manipulation by the operator
Parameter identification (ID-Run) Main controller ███ ███ ███ █ █ Signal of the control during active parameter identification (ID-Run) > Event due to manipulation by the operator
Demag Cranes Components GmbH Product Support Dept.1922 09.05.2009(wit) Seite 1 von 6
Flash codes of radio receiver card
Normal operation Radio module Green LED flashes Normal operation, receiving valid data
Receiving incorrect data Radio module Red LED flashes Receiving incorrect data
Searching for transmitter Radio module Orange LED flashes Receiver searching for active hand-held transmitters
Safe status Radio module Individual red LED permanently on Controller of radio receiver card has detected critical error status
Error codes of radio receiver card

Message Meaning (p g Possible causes
950 Monitoring controller of radio receiver card has detected missing objects on - Other Can bus subscriber not working
Flash codes of DRC-10 hand-held transmitter

Normal operation DRC-10 LED flashes green Normal operation, hand-held transmitter functioning
Stop DRC-10 LED lit red Stop status after actuation of Stop key. Hand-held transmitter in "Stop mode"
De-activated DRC-10 LED off Hand-held transmitter switched off or blocked ("Off mode")
Encoding of messages from DR control systems

Display of "negative" load values after taring: The load display alternates between the load value and the value 0.00
Distinction between error and warning messages for operation with PRC
Message Meaning Description
1 to 99 Error message DR control has detected an error or a problem and only allows emergency operation or stops at least one axis
101 to 199 Warning message A hoist or trolley motion cannot be carried out owing to an operating status (e.g. limit switch, overload)
Assignment of source of a message shown in the display for manual control

Message Only one trolley One of two trolleys selected Both trolleys selected
1 to 99 Message of trolley Message of selected trolley Message of trolley 1
101 to 199 Message of crane Message of crane Message of crane
201 to 299 Not possible Message of not selected trolley Message of trolley 2
901 to 999 Messages of radio remote control system
To identify the origin, 100 is added to the error code by the crane control system and 200 by the control system of the other trolley.
Attention:The error codes are entered into the error memory of each control system without this added origin identification.
Assignment of messages to controllers of a DR control system

Message is created by
x01 to x63 Main controller HCS12

x63 to x99 Monitoring controller PIC
Code
Active Crane 2nd PRC Source Display Signal horn Description Possible malfunction / causes Behaviour of control system
trolley trolley
1 101 201 - Main controller crane or trolley(s) Impossible ███ █ CAN bus error, CAN bus has not reached normal operating mode - Check Can bus connection ( plug loose / cable defective / ... ) Crane contactor is switched off
2 102 202 - Main controller crane or trolley(s) Impossible ███ █ CAN bus error, CAN bus passive or buffer overflows in CAN communication - CAN bus connection incorrect Crane contactor is switched off
3 103 203 3 Main controller crane or trolley(s) Yes K1 shows unexpected behaviour (does not pull up, does not drop, generation of control voltage> K1 defective or K1 wiring incorrect Up to SW V2.47 => emergency operation (lowering V1) and
feedback contact) > Configuration of DR control (jumper / bridges) incorrect message
> Parameter seting does not correspond to the limit switch variant From SW V3.00 => emergency operation, message and
> DR control system error (replace control system) removal of enable in the case of parallel operation
4 204 4 Main controller trolley(s) Yes Thermal contact of hoist motor tripped - Motor overheated Emergency operation (lowering V1)
- Thermal contact defective
- Connection to motor defective
104 Main controller crane Yes Thermal contact of crane motor tripped See error 4 Cranes stops
- Short-circuit bridge missing for motors without thermal contact
5 105 205 5 Main controller crane or trolley(s) Yes Hardware error: One output of controller does not assume required status - DR control system error (replace control system) Crane contactor is switched off
6 206 6 Main controller trolley(s) Yes Max. permissible braking distance of hoist unit exceeded - Check brake Reduced operation (lifting or lowering at V1)
- Parameter error
106 Main controller crane Yes Max. permissible braking distance of crane exceeded (only with rotary encoder) Implementation not possible due to missing encoder does not exist
7 207 Main controller crane or trolley(s) Maximum permitted path difference between two hoists in simultaneous operation exceeded - Simultaneous operation not possible due to mechanical or electrical problems Hoist stops
- "Maximum simultaneous running difference" parameter defective
- Inverter defective or incorrectly programmed
8 208 108 Main controller trolley(s) Yes While unloading hoist unit, value dropped below slack rope switching point - Spreader lowered with active slack rope function Lowering no longer possible
- Incorrect parameter programming (dead load / ZMS setting values / reeving /... )
- External interference (EMC)
- Load detection (ZMS) defective
9 209 9 Main controller trolley(s) Yes Software error: Data for ZMS evaluation not correctly initialized - Incorrect parameter programming Lifting no longer possible + "Parameter error" horn sequence
or distorted at a later date - DR control system error (replace control system)
10 210 10 Main controller trolley(s) Yes Measuring value of ZMS 1 with empty hook too small - Incorrect parameter programming (ZMS offset) Lifting no longer possible
11 211 11 Main controller trolley(s) Yes Measuring value of ZMS 2 with empty hook too small See error 10 Lifting no longer possible
12 212 12 Main controller trolley(s) Yes Monitoring system of +/-12 V supply for ZMS has detected an error - External interference (EMC) Lifting no longer possible
13 213 13 Main controller trolley(s) Yes Error on ZMS evaluation detected during check caused by deviation > Load detection (ZMS) defective Lifting no longer possible
> ZMS wiring defective
> DR control system error (replace control system)
(Error is retained for approx. 3 minutes)
14 214 14 Main controller trolley(s) Yes Load difference between two hoist units too large - Normal operating status Lifting no longer possible
- Parameter error
15 215 15 Main controller trolley(s) Yes Main controller has detected overload, monitoring controller not (yet) - DR control system error (replace control system) Lifting no longer possible
16 116 216 16 Main controller crane or trolley(s) not yet used not yet used not yet used
17 217 17 Main controller trolley(s) Yes Evaluation rotary encoder lifting: Setpoint value available, however, axis at standstill - Motor not turning Hoist stops
- Motor cable defective
- Rotary encoder defective
- Rotary encoder cable defective
- Rotary encoder amplifier module defective
18 218 18 Main controller trolley(s) Yes Evaluation rotary encoder lifting: No setpoint value available, however, axis not at standstill - Motor turning without setpoint value specification (detail analysis required) Crane contactor is switched off
19 219 19 Main controller trolley(s) Yes Evaluation rotary encoder lifting: Setpoint value available and axis travels too fast - Motor turning faster than setpoint value Hoist stops
- Parameter error (50 / 60 Hz settings)
- Line frequency fluctuation
- Rotary encoder, driver module or cable defective
- DIP switch 7 set wrong
20 220 20 Main controller trolley(s) Yes Hoist FI signals an error, the precise error description can be read in the error memory of the - Message of inverter after actuation of emergency stop Hoist stops
hoist FI via PC software - Other inverter error. The precise error description can be read in the error memor
of the hoist FI via PC software
21 221 21 Main controller trolley(s) Yes Trolley inverter does not signal to be ready. Possible causes: Thermal contact - Check travel motor thermal contact Trolley stops
121 Main controller crane Yes Crane inverter does not signal to be ready. Possible causes: Thermal contact Read
See o t19
error in erter error memor sing PC soft are Crane stops
Code
trolley trolley
22 222 22 Main controller trolley(s) Yes Evaluation rotary encoder lifting: Setpoint value available and axis travels too slow - Brake defective Hoist stops
- Parameter error (50 / 60 Hz settings or rated speed)
- Rotary encoder cable defective
- Rotary encoder amplifier module defective
23 223 23 Main controller trolley(s) Yes Overcurrent contact of one braking resistor tripped (hoist FI) - Hoist inverter defective Crane contactor is switched off
- Overcurrent contact defective
- Overcurrent contact tripped
- Inverter / overcurrent contact connection defective
24 224 24 Main controller trolley(s) Yes Hex switch value invalid (larger 15) - DR control system error (replace control system) Hoist stops
25 125 225 25 Main controller crane or trolley(s) as required Programmed parameters do not match hardware configuration (for modular hardware) - Parameter error Crane contactor is switched off
- Control system fitted with incorrect modules
- Module defective (replace module)
26 126 226 26 Main controller crane or trolley(s) Yes Error of dynamic monitoring of safety relevant signals (ODDS) - DR control system error (replace control system) Reduced operation (lifting or lowering at V1)
27 227 27 Main controller trolley(s) Impossible ███ █ █ █ Parameter missing or has invalid value, detected by check-sum check - Parameter error Crane contactor is switched off
127 Main controller crane Impossible Crane has no signal horn Parameter missing or has invalid value, detected by check-sum check - Parameter error Crane contactor is switched off
28 128 228 28 Main controller crane or trolley(s) as required ███ █ █ █ █ █ DIP switch 5 in incorrect position or incorrect parameter setting of crane/trolley - Parameter error (trolley - crane setting) Error message and horn signal
- Dip switch 5 incorrectly set
29 129 229 29 Main controller crane or trolley(s) K2 switching status monitoring has detected deviation from expected switching status For ISS: DR control system error (replace control system) Up to SW V2.47 => hoist stops but no info to hoist unit working
for HSS: in parallel
- K2 defective (replace contactor set) From SW V3.00 => hoist stops, removal of enable in the case
- Cable loom to contactor set defective (replace contactor set) of parallel operation
30 130 230 30 Main controller crane or trolley(s) K3 switching status monitoring has detected deviation from expected switching status For ISS: DR control system error (replace control system) Up to SW V2.47 => hoist stops but no info to hoist unit working
for HSS: in parallel
- K3 defective (replace contactor set) From SW V3.00 => hoist stops, removal of enable in the case
- Cable loom to contactor set defective (replace contactor set) of parallel operation
31 231 31 Main controller trolley(s) Yes Monitoring contact of hoist brake signals an impermissible brake release - Brake / brake coil defective Hoist stops
- Micro switch (brake release contact) incorrectly set
33 233 33 Main controller trolley(s) Yes Hardware error ZMS1 / SGS: - ZMS defective Lifting no longer possible
> ZMS: ZMS defective, not connected or has broken wire - ZMS not connected
> SGS: Frequency of signal for detection of switching status of SGS too high - ZMS conductor broken
- Parameter error
- EMC interference- DR control system error (replace control system)
34 234 34 Main controller trolley(s) Yes | | | | | | | | | | | | etc. Emergency limit switch top tripped without Limit switch check - Limit switches incorrectly set Hoist unit is stopped until the next time it is switched off and on
- Jumper settings wrong for limit switches again.
- Parameter error
- Error when checking limit switches (incorrect sequence)
- Geared limit switch / cable defective
35 235 35 Main controller trolley(s) Yes | | | | | | | | | | | | etc. Emergency limit switch bottom tripped without Limit switch check See error 34 Hoist unit is stopped until the next time it is switched off and on
again.
36 236 36 Main controller trolley(s) Yes Monitoring contact of hoist brake signals that brake cannot be released - Brake / brake coil defective Hoist stops
- Micro switch (brake release contact) incorrectly set
- Motor protection switch not switched on
- Motor supply cable defective
38 238 38 Main controller trolley(s) Yes Evaluation rotary encoder lifting: Setpoint value available and axis moves into wrong direction - Phases swapped Hoist stops
- Rotary encoder defective Attention: Error stored until next start-up!
40 240 40 Main controller trolley(s) Yes OK of crane for switching K1 on via CAN bus missing - Can bus defective (see error 1) Hoist stops
- Parameter error (crane, trolley, solo travelling hoist)
- Dip switch 5 incorrectly set
- Crane control system failed (e.g. no control voltage)
- Consequential error following crane control system error
140 Main controller crane Yes OK of min. one trolley for switching the crane contactor on via CAN bus missing See error 40 Crane contactor is switched off
- Consequential error following trolley control system error
41 241 141 Main controller trolley(s) Internal control system message on overload Internal control system message on overload Lifting no longer possible
42 242 42 Main controller trolley(s) yes Hardware error ZMS2: ZMS defective, not connected or has broken wire See error 33 Lifting no longer possible
Code
trolley trolley
43 143 243 43 Main controller crane or trolley(s) yes Error of double limit switch monitoring system > Limit switches/actuators incorrectly fitted Only limited emergency operation still possible (lowering and
>Limit switches defective travelling at small speed).
>Cable connection to limit switch defective Attention: Error is saved until the next start-up.
>Parameters, jumpers and limit switch configuration do not match
>DR control system error (replace control system)
144 Main controller crane Yes Error in switching sequence of crane limit switches - Limit switches/actuators incorrectly fitted Message only
- Limit switches defective
- Cable connection to limit switch defective
- Parameters, jumpers and limit switch configuration do not match
44 244 44 Main controller trolley(s) Yes Error in switching sequence of trolley limit switches - Limit switches/actuators incorrectly fitted Message only
- Limit switch, supply line or connector defective
- Parameters and limit switch configuration do not match
- Short circuit protection Usichi has switched off (briefly)
45 145 245 45 Main controller crane or trolley(s) Yes Error in switching sequence of hoist limit switches - Geared limit switch incorrectly adjusted Message only
- Geared limit switch defective
- Cable connection to limit switch defective
- Parameters, jumpers and limit switch setting do not match
46 146 246 46 Main controller crane or trolley(s) as required ███ █ █ █ █ Software of monitoring controller deviates from planned time behaviour - DR control system error (replace control system) Hoist stops
47 147 247 47 Main controller crane or trolley(s) as required ███ █ █ The number of safety relevant control signals has exceeded the limit value - 2 CAN control sources are connected to the CAN bus Crane contactor is switched off
48 48 Main controller trolley (Impossible) Communication error to PRC/automatic crane - Check Can bus connection ( plug loose / cable defective / ... ) All movements are stopped (control system acts as if
- PRC/automatic crane not working emergency stop was actuated)
- Connection to PRC/automatic crane not working
49 149 249 49 Main controller crane or trolley(s) Synchronous operation timeout - Error in exchange of position values between hoist units Hoist stops
50 150 250 50 Main controller crane or trolley(s) STOP DSE: ███ █ █ With CAN bus: Bus not active, SRDO error or emergency stop activated - Operating condition when switched on, if Emergency-stop on DSE is pressed All movements are stopped
Parallel control: Emergency stop actuated (DSE8-R)
- See error 1
- Consequential error following safety-relevant malfunction of another CAN
subscriber
51 151 251 51 Main controller crane or trolley(s) Yes Monitoring contact of crane contactor signals that crane contactor does not pull up - Crane contactor not pulling up properly Crane contactor remains switched off
- Error in connection to crane contactor
- Crane contactor feedback contact defective
- Jumper for NoEmergencyStop signal (J101) incorrectly fitted or missing
52 152 252 52 Main controller crane or trolley(s) Poss. only RC10: ███ █ █ Error while exchanging safety-relevant information via CAN bus: SRDO missing; sequence, See error 50 Crane contactor is switched off
for RC10 time behaviour or SRDO contents incorrect
53 153 253 53 Main controller crane or trolley(s) Yes Monitoring contact of crane contactor signals that crane contactor does not drop - Crane contactor not dropping properly All movements are stopped or prevented
- Error in connection to crane contactor
- Crane contactor feedback contact defective
54 154 254 54 Main controller crane or trolley(s) Yes Warning "impermissible operation" One of the following impermissible functions has been caused: Response of DR control system:
- Limit switch check with both hoist units at the same time - Lifting and lowering motions are prevented
55 155 255 55 Main controller crane or trolley(s) Yes Warning "Timeout after travel command": After a travel command, the travel motion was not > Another trolley blocks travel owing to malfunction or similar in the case of parallelMotion of the axis concerned is not started
started within the permissible time and therefore is prevented by the control system for safety operation
reasons > other parameter or hardware errors
> Signal time before travel start only programmed for one of the two trolleys
56 256 156 Main controller trolley(s) Yes Load detection window not reached in permitted time - Binding brake, If incorrect parameters have been detected, the hoist stops
- Tight movement in gearbox
- Incorrect DR parameter values:
+ “E_063_02” DR parameter line frequency not 50 or 60 Hz
+ “E_063_03” DR parameter hoist motor rated speed V1
+ “E_063_04” DR parameter hoist motor rated speed V2
57 257 157 Main controller trolley(s) Yes "Parameter for load detection via slip evaluation incorrect" error - At least one load detection parameter has non-permitted value If incorrect parameters have been detected, the hoist stops
58 258 158 Main controller trolley(s) Yes Warning "Limit switch check aborted" - Limit switch check not completed Operating limit switch active again (can also be acknowledged
- “Limit switch check” signal missing via STOP key)
59 159 259 159 Main controller crane or trolley(s) Yes Warning "Catching brake": Lowering not possible, as catching brake has tripped. - Catching brake really tripped Hoist can only lift at slow speed
- Signal contact/actuation defective
- Cable to contact defective/not correctly connected
- Jumper setting incorrect
- Catching brake parameters programmed, but none available
60 160 260 160 Main controller crane or trolley(s) Yes Warning "While in limit switch": Moving in selected direction not possible, limit switch reached. - Limit switch really reached Movement in the direction switched off by the limit switch no
- Limit switch or actuation defective longer possible
- Cable to limit switch defective / not correctly connected
- Jumper setting incorrect
- Incorrect parameters programmed
Code
trolley trolley
61 161 261 161 Main controller crane or trolley(s) Yes Warning "Stop due to blocked area": Motion in selected direction is prevented by by-pass - Entry into blocked area attempted Movement in the direction of the blocked area no longer
control system. - Area switch or actuation defective possible
- Cable to area switch defective / not correctly connected
62 162 262 162 Main controller crane or trolley(s) Yes Warning "Stop since load is too large for reduced load area": Moving in selected direction - Load too large for area with load reduction Movement in the direction of the area with reduced load no
prevented, since load is too large for this area. - Area switch or actuation defective longer possible
- Cable to area switch defective / not correctly connected
- Load detection defective (see overload)
63 163 263 163 Main controller crane or trolley(s) Yes Warning "Inverter interface not available yet" Operational message every time the crane is switched on. May also be caused by If no parameters can be read from the inverter, no lifting
Moving in selected direction not possible, because necessary hoist inverter parameters: - Error in CAN connection to hoist inverter movement is possible
- have not been read or are incorrectly programmed. - Parameter 830 "Load spectrum operating mode" is programmed to "Off" instead
64 164 264 64 Mon. controller crane or trolley(s) Yes Hardware error: Watchdog of monitoring controller not working - DR control system error (replace control system) Reduced operation (lifting or lowering at V1)
65 165 265 65 Mon. controller crane or trolley(s) Yes Hardware error: As output of monitoring controller for controlling crane contactor is not working- DR control system error (replace control system) Reduced operation (lifting or lowering at V1)
only emergency operation of all axes possible
66 166 266 66 Mon. controller crane or trolley(s) Yes Owing to error of dynamics monitoring of safety-relevant signals (ODDS), only emergency - ODDS signal (dynamic monitoring of the limit switches) defective Reduced operation (lifting or lowering at V1)
operation of all axes, ODDS bridge may be missing on connector of an unused input (UniIn or - ODDS bridge missing on an unused limit switch
limit switch) - Limit switches defective
67 167 267 67 Mon. controller crane or trolley(s) Yes Parameters transmitted from HCS12 to PIC or reference values are not > Parameter error Reduced operation (lifting or lowering at V1)
usable. Therefore, only emergency operation is possible > Error in calculation of reference values
> Detection of +/- 12 V for ZMS defective
68 168 268 68 Mon. controller crane or trolley(s) Yes Only emergency operation permissible owing to error of trolley motor contactor - No longer active, since trolley motor contactor left out Reduced operation of trolley (travel at V1)
(remove trolley motor contactor, if required)
70 170 270 70 Mon. controller crane or trolley(s) Yes Hardware error: As feedback of K1 control is missing, only emergency operation of K1 axis - Contactor incorrectly connected after K1 replaced Reduced operation (lifting or lowering at V1)
possible - DR control system error (replace control system)
71 171 271 71 Mon. controller crane or trolley(s) Yes Hardware error: As monitoring controller cannot de-activate the brake, only emergency - DR control system error (replace control system) Reduced operation (lifting or lowering at V1)
operation of K1 a is permissible
72 172 272 72 Mon. controller crane or trolley(s) Yes K1 feedback remains active, for K1 axis only emergency operation See error 70 Reduced operation (lifting or lowering at V1)
73 273 73 Mon. controller trolley(s) Yes Hardware error: Only emergency operation of hoist unit owing to ZMS or SGS error See error 33 Hoist can only lift at slow speed
74 274 74 Mon. controller trolley(s) Yes Emergency limit switch tripped without Limit switch check being active see errors 34 and 35 Reduced operation (lifting or lowering at V1)
75 175 275 75 Mon. controller crane or trolley(s) Yes Hardware error: Trolley motor contactor does not pick up - No longer active, since trolley motor contactor left out Trolley stops
76 176 276 76 Mon. controller crane or trolley(s) Yes Hardware error: As monitoring controller cannot enable the brake, operation of hoist unit not See error 71 Hoist stops
possible
77 177 277 77 Mon. controller crane or trolley(s) Yes Hardware error: K1 does not pick up See error 3 Hoist stops
78 278 78 Mon. controller trolley(s) Yes Direction of revolution error Lifting: See error 38 Hoist stops
179 Mon. controller crane Yes OK of min. one trolley for switching the crane contactor on via CAN bus missing See error 140 Crane contactor is switched off
80 280 80 Mon. controller trolley(s) Yes OK of crane for switching K1 on via CAN bus missing See error 40 All movements are stopped
81 281 181 Mon. controller trolley(s) Yes Monitoring controller has detected overload, main controller not (yet) - DR control system error (replace control system) Hoist can only lift at slow speed
82 282 82 Mon. controller trolley(s) Yes Main controller causes motions of hoist unit without the corresponding control commands being- DR control system parameter error Hoist stops
available - Inverter parameter error
83 283 83 Mon. controller trolley(s) Yes Monitoring controller has detected that main controller causes motions of the travelling hoist > DR control system parameter error (speed V1 too high) Trolley stops
without the corresponding control commands being available > For older SW version: Crab selection changed during travel
183 Mon. controller crane Yes Monitoring controller has detected that main controller causes motions of the crane without the> DR control system parameter error (speed V1 too high) Crane stops
corresponding control commands being available > Inverter parameter error
84 184 284 84 Mon. controller crane or trolley(s) Yes Hardware error: Output of monitoring controller for switching off the crane contactor is active (o- DR control system error (replace control system) Hoist stops
in modular hardware the output for switching off the CAN bus), this causes CAN bus to be
blocked
85 185 285 85 Mon. controller crane or trolley(s) Yes Event: Command from main controller to assume safe status was received - Response of main controller to external interference (EMC) All movements are stopped
86 186 286 86 Mon. controller crane or trolley(s) Yes Software of main controller deviates from planned time behaviour - DR control system error (replace control system) Hoist stops
87 187 287 87 Mon. controller crane or trolley(s) Yes Monitoring system of main controller has detected an error or a missing response of main - DR control system error (replace control system) Hoist stops
88 88 Mon. controller trolley (Impossible) controller
Communication error to PRC/automatic crane See error 48 Crane contactor is switched off
89 189 289 89 Mon. controller crane or trolley(s) Yes Hardware error: Monitoring controller has detected own HW error - DR control system error (replace control system) All movements are stopped
90 190 290 90 Mon. controller crane or trolley(s) as required Emergency stop / STOP actuated during axis movement (for CAN bus, bus may not be active, Emergency stop / STOP actuated during axis movement Crane contactor is switched off
or SRDO error)
91 191 291 91 Mon. controller crane or trolley(s) Yes Error of crane contactor: K1 and KMS are switched off See error 51 Hoist stops
92 192 292 92 Mon. controller crane or trolley(s) Yes Error while exchanging safety-relevant information via CAN bus: SRDO missing; sequence, See error 50 Crane contactor is switched off
93 193 293 93 time beha io r or SRDO contents incorrec
Mon. controller crane or trolley(s) Yes Monitoring contact of crane contactor signals that crane contactor does not drop See error 53 All movements are stopped
94 194 294 94 Mon. controller crane or trolley(s) Yes Monitoring contact of K1 signals that K1 does not drop See error 3 Crane contactor is switched off
95 195 295 95 Mon. controller crane or trolley(s) Yes KMS trolley motor contactor does not drop, crane contactor is switched off - No longer active, since trolley motor contactor left out Crane contactor is switched off
96 196 296 96 Mon. controller crane or trolley(s) as required Monitoring controller has detected complete failure of main controller - DR control system error (replace control system) Crane contactor is switched off
97 197 297 97 Mon. controller crane or trolley(s) not yet used not yet used
Warning and error codes of the DPC module
(Parallel IN)
Flash codes of main controller ( green LED, operating statuses )
Status Source Flash code Description possible malfunction / causes
Normal operation Main controller █ (1x) Normal operation - Normal operating status
Only V1 / axis Main controller ██ (2x) Limitations for operation of at least one axis - Failure of a monitoring function (see error code)
Only V1 all axes Main controller ███ (3x) Limitations for operation of trolley, crane and hoist axis - Failure of a monitoring function (see error code)
No travel command(s) Main controller ████ (4x) No travel motions of at least one axis - Failure of a monitoring function (see error codes)
No travel commands and F keys Main controller █████ (5x) No travel motions of trolley, crane and hoist axis and function keys - Key operated during stop
Stop Main controller ██████ (6x) No operation of all axes, transmission of stop on CAN bus - Failure of a safety-relevant function (see error codes)
Monitoring controller error Main controller █ █ █ █ █ █ █ █ (8x) Main controller has detected incorrect behaviour of monitoring controller - DPC error (replace device)
CAN not ok Main controller █ █ █ █ █ █ █ █ █ (9x) Main controller has detected error of CAN bus - Check CAN bus connection ( plug loose / cable defective / ... )
- other CAN bus subscriber not working
- Incorrect setting ( Parameter / Dip switch / final resistor / ... )
Flash codes of monitoring controller (blue LED )

Status Source Flash code Description possible malfunction / causes
Normal operation Mon. controller █ Normal operation - Normal operating status
Operation in debug mode Mon. controller █ █ Monitoring controller working with debug software - DPC error (replace device)
- DPC error (replace device)
Watchdog or HW error Mon. controller ██████████ etc. Monitoring controller not operational owing to watchdog or HW error - DPC error (replace device)
Error message Mon. controller █ █ █ █ █ █ etc. Monitoring controller has detected and reported error condition to main controller - Condition when error detected (see error code)
Encoding of messages from DPC

1 to 63 Main controller HCS12
64 to 99 Monitoring controller PIC

Message Source Type Description possible malfunction / causes
1 Main controller Error DPC not started, CAN bus has not reached normal operating mode - Check CAN bus connection ( plug loose / cable defective / ... )
- other CAN bus subscriber not working
- Incorrect setting ( Parameter / Dip switch / final resistor / ... )
2 Main controller Error CAN bus error, CAN bus passive or buffer overflows in CAN communication - CAN bus connection incorrect
- Other bus subscriber incorrect
- Incorrect setting ( Parameter / Dip switch / final resistor / ...
3 Main controller Error Impermissible parameter in CAN initialisation - DPC error (replace device)
4 - - - -
5 Main controller Error Hardware error: One output of controller does not assume required status - DPC error (replace device)
6 - - - -
7 - - - -
8 - - - -
9 - - - -
10 Main controller Error Forced zero position of all keys when unlatching STOP - A key is actuated during activation of STOP
- Release causing key
- Actuate STOP and unlatch again
- DSE-10 error (replace control pendant)
11 - - -
12 - - -
13 - - -
14 - - -
15 - - -
16 Main controller Error Monitoring controller does not respond in expected time behaviour - DPC error (replace device)
17 - - -
18 - - -
19 - - -
20 Main controller Error Monitoring controller reports an invalid software version - DPC error (replace device)
21 - - -
22 - - -
23 Main controller Error Both keys are actuated in hoist axis - Keys for lifting and lowering actuated at the same time
24 Main controller Error Both keys are actuated in trolley axis - Keys for right and left are actuated at the same time
25 Main controller Error Both keys are actuated in crane axis - Keys for forward and backward are actuated at the same time
26 - - -
27 - - -
Product Support Dept.1922

Demag Cranes Components GmbH 09.05.2009(wit) Page 1 of 3
(Parallel IN)
28 Main controller Error Analogue values from main and monitoring controller for the hoist differ - External interference
29 Main controller Error Analogue values from main and monitoring controller for the trolley differ - External interference
30 Main controller Error Analogue values from main and monitoring controller for the crane differ - External interference
31 Main controller Error Main controller detects deviation of IOs during comparison with monitoring controller - External interference
32 - - - -
33 - - - -
34 - - -
35 Main controller Error Plausibility monitoring of analogue values has detected deviation in the hoist - Analogue reference value incorrec
36 Main controller Error Plausibility monitoring of analogue values has detected deviation in the trolley - Analogue reference value incorrec
37 Main controller Error Plausibility monitoring of analogue values has detected deviation in the crane - Analogue reference value incorrec
38 - - -
39 - - -
40 - - -
41 - - -
42 Main controller Main controller has detected an error during the cyclical test of its analogue port - External interference
43 Main controller Event "STOP" actuated - Normal operating status
- Unlatch STOP and actuate again
44 Main controller Error Main controller detects a different STOP from monitoring controller. - DPC error (replace device)
45 - - -
46 Main controller Error Software of monitoring controller deviates from planned time behaviour - DPC error (replace device)
47 - - -
48 - - -
49 - - -
50 - - -
51 - - -
52 - - -
53 - - -
54 - - -
55 - - -
56 - - -
57 - - -
58 - - -
59 - - -
60 - - -
61 - - -
62 - - -
63 - - -
64 Monitoring controller Error Hardware error: WatchDog of monitoring controller not working - DPC error (replace device)
65 Monitoring controller Error Hardware error: As output of monitoring controller for enabling CAN transmission reports a - DPC error (replace device)
non-permitted level, only emergency operation of all axes permitted (passive)
66 - - - -
67 Monitoring controller Error Only emergency operation of all axes owing to parameter error - Parameter error
68 Monitoring controller Error Analogue value monitoring for the hoist has detected deviation - External interference
69 Monitoring controller Error Analogue value monitoring for the trolley has detected deviation - External interference
70 Monitoring controller Error Analogue value monitoring for the crane has detected deviation - External interference
71 Monitoring controller Error Monitoring controller has detected deviation of IOs - External interference
72 - - - -
73 - - - -
74 - - - -
75 - - - -
76 - - - -
77 - - - -
78 - - - -
80 - - - -
81 Monitoring controller Error Hardware error: Output of monitoring controller for enabling CAN transmission reports a non- - DPC error (replace device)
permitted level (active)
82 Monitoring controller Error Cyclical analogue port test has detected deviation - External interference
83 Monitoring controller Event "STOP" actuated - Normal operating status
- Unlatch STOP and actuate again
84 Monitoring controller Error Monitoring controller detects deviation regarding "STOP" to monitoring controller - DPC error (replace device)
85 Monitoring controller Error Event: Command from main controller to assume safe status - DPC error (replace device)
was received
86 Monitoring controller Error Software of main controller deviates from planned time behaviour - DPC error (replace device)

(Parallel IN)
87 Monitoring controller Error Monitoring system of main controller has detected an error or a missing response of main - DPC error (replace device)
controller
88 Monitoring controller Error Travel reference values of main controller deviate from statuses determined by monitoring - DPC error (replace device)
controller.
89 Monitoring controller Error Hardware error: Monitoring controller has detected own HW error - DPC error (replace device)
90 Monitoring controller Error Monitoring controller has detected a difference of "STOP" on CAN bus compared with its own - Normal operating status
IOs (passive) - Consequential error
91 - - - -
92 Monitoring controller Error Error while exchanging safety-relevant information via CAN bus: SRDO missing; sequence, - See error 1 + 2
time behaviour or SRDO contents incorrect
93 - - - -
94 Monitoring controller Error Monitoring controller has detected a difference of "STOP" on CAN bus compared with its own - DPC error (replace device)
IOs (active)
95 - - - -
96 Monitoring controller Error Monitoring controller has detected complete failure of main controller - DPC error (replace device)
97 - - - -
98 - - - -
99 - - - -

DSE-10 error and status messages
Flash codes of main controller (green LED, operating statuses)

Normal operation Main controller █ (1x) Normal operation - Normal operating status
Only V1 crane Main controller █ █ (2x) Limitations for operation of crane axis - Failure of a monitoring function (see error code
Only V1 trolley Main controller █ █ █ (3x) Limitations for operation of trolley axis - Failure of a monitoring function (see error code
Only V1 hoist Main controller █ █ █ █ (4x) Limitations for operation of hoist axis - Failure of a monitoring function (see error code
Emergency operation Main controller █ █ █ █ █ (5x) Limitation for operation of all axes - Failure of a monitoring function (see error codes
No travel commands Main controller █ █ █ █ █ █ (6x) No travel motions permitted, stop remains unaffected - Key actuated during stop
Stop Main controller █ █ █ █ █ █ █ (7x) No operation of all axes, transmission of stop on CAN bus - Failure of a safety-relevant function (see error codes
Monitoring controller error Main controller █ █ █ █ █ █ █ █ (8x) Main controller has detected incorrect behaviour of monitoring controller - DSE-10 error (replace pendant)
CAN not ok Main controller █ █ █ █ █ █ █ █ █ (9x) Main controller has detected error of CAN bus - Check Can bus connection ( plug loose / cable defective / ... )
Flash codes of monitoring controller (blue LED)

Normal operation Mon. controller █ Normal operation - Normal operating status
Operation in Debug mode Mon. controller █ █ Monitoring controller working with Debug software - DSE-10 error (replace pendant)
- DSE-10 error (replace pendant)
Watchdog or HW error Mon. controller ██████████ etc. Monitoring controller not operational owing to watchdog or HW error - DSE-10 error (replace pendant)
Error message Mon. controller █ █ █ █ █ █ etc. Monitoring controller has detected and reported error condition to main controller - Condition when error detected (see error code
Encoding of messages from DSE-10

1 to 63 Main controller HCS12
64 to 99 Monitoring controller PIC
Warning and error codes of the DSE-10

Message Source Type Description Possible malfunction / causes
1 Main controller Error DSE-10 not started, CAN bus has not reached normal operating mode
- Check Can bus connection ( plug loose / cable defective / ... )
2 Main controller Error CAN bus error, CAN bus passive or buffer overflows in CAN communication - CAN bus connection incorrec
- Other bus subscriber incorrect
- Incorrect setting ( parameters / Dip switches / final resistor / ...
3 Main controller Error Impermissible parameter in CAN initialisation - DSE-10 error (replace pendant)
4 - - - -
5 Main controller Error Hardware error: One output of controller does not assume required status - DSE-10 error (replace pendant)
6 - - - -
7 - - - -
8 - - - -
9 - - - -
10 Main controller Error A key is actuated during activation of STOP - Normal operating status
- Release causing key
- Unlock STOP and actuate again
11 - - -
12 - - -
13 - - -
14 - - -
15 - - -
16 Main controller Error Monitoring controller does not respond in expected time behaviour - DSE-10 error (replace pendant)
17 - - -
18 - - -
19 - - -
20 Main controller Error Monitoring controller reports an invalid software version - DSE-10 error (replace pendant)
21 - - -
22 - - -
23 - - -
24 - - -
25 - - -
26 - - -
27 Main controller Error Parameter error - Check and correct parameter
28 Main controller Error Analogue values from main and monitoring controller for the hoist differ - External interference
29 Main controller Error Analogue values from main and monitoring controller for the trolley differ - External interference

Demag Cranes Components GmbH 09.05.2009 (wit) Seite 1 von 3
30 Main controller Error Analogue values from main and monitoring controller for the crane differ - External interference
31 Main controller Error Main controller detects deviation of IOs during comparison with monitoring controller - STOP contact problems
- External interference
32 - - - -
33 - - - -
34 - - -
35 Main controller Error Plausibility monitoring of analogue values has detected deviation in the hoist - Magnet missing
- Magnet pole reversal
36 Main controller Error Plausibility monitoring of analogue values has detected deviation in the trolley - Magnet missing
37 Main controller Error Plausibility monitoring of analogue values has detected deviation in the crane - Magnet missing
38 - - -
39 - - -
40 - - -
41 - - -
42 Main controller Main controller has detected an error during the cyclical test of its analogue port - External interference
43 Main controller Event "STOP" actuated - Normal operating status
44 Main controller Error Main controller detects a different STOP from monitoring controller. - Dirt on emergency stop contacts
- Lock and unlock emergency stop several times
45 - - -
46 Main controller Error Software of monitoring controller deviates from planned time behaviour - DSE-10 error (replace pendant)
47 - - -
48 - - -
49 - - -
50 - - -
51 - - -
52 - - -
53 Main controller Warning Data error for IrDA transmission detected - External interference
- IrDA not correctly aligned
54 Main controller Warning End code for IrDA transmission not received - External interference
55 Main controller Warning Check-sum error for IrDA transmission - External interference
56 Main controller Warning Check-sum error between internal and external check sum - External interference
57 Main controller Error CAN service is not available (SDO) - DSE-10 error (replace pendant)
58 Main controller Warning Requested SDO service does not exist - Idapsy sends trash
59 Main controller Warning Rope hoist to be addressed not within definition range - Idapsy sends trash
60 Main controller Warning Timeout of CAN transmission during reading - Normal operating status (= addressed subscriber not available
61 Main controller Warning Timeout of CAN transmission during writing - External interference
62 - - -
63 - - -
64 - - -
65 Monitoring controller Error Hardware error: As output of monitoring controller for enabling CAN transmission reports a non-
permitted level, only emergency operation of all axes permitted (passive)
66 - - - -
67 Monitoring controller Error Only emergency operation of all axes owing to parameter error - Parameter error
68 Monitoring controller Error Analogue value monitoring for the hoist has detected deviation - External interference
69 Monitoring controller Error Analogue value monitoring for the trolley has detected deviation - External interference
70 Monitoring controller Error Analogue value monitoring for the crane has detected deviation - External interference
71 Monitoring controller Error Monitoring controller has detected deviation of IOs - Dirt on STOP contacts
72 - - - -
73 - - - -
74 - - - -
75 - - - -
76 - - - -
77 - - - -
78 - - - -

80 - - - -
81 Monitoring controller Error Hardware error: Output of monitoring controller for enabling CAN transmission reports a non- - DSE-10 error (replace pendant)
permitted level (active)
82 Monitoring controller Error Cyclical analogue port test has detected deviation - External interference
83 Monitoring controller Event "STOP" actuated - Normal operating status
84 Monitoring controller Error Monitoring controller detects deviation regarding "STOP" to monitoring controller - Dirt on emergency stop contacts
- Lock and unlock emergency stop several times
85 Monitoring controller Error Event: Command from main controller to assume safe status was received - DSE-10 error (replace pendant)
86 Monitoring controller Error Software of main controller deviates from planned time behaviour - DSE-10 error (replace pendant)
87 Monitoring controller Error Monitoring system of main controller has detected an error or a missing response of main - DSE-10 error (replace pendant)
controller
88 - - - -
89 Monitoring controller Error Hardware error: Monitoring controller has detected own HW error - DSE-10 error (replace pendant)
90 Monitoring controller Error Monitoring controller has detected a difference of "STOP" on CAN bus compared with its own - Normal operating status
IOs (passive) - DSE-10 error (replace pendant)
91 - - - -
92 Monitoring controller Error Error while exchanging safety-relevant information via CAN bus: SRDO missing; sequence, - See error 1 + 2
time behaviour or SRDO contents incorrect
93 - - - -
94 Monitoring controller Error Monitoring controller has detected a difference of "STOP" on CAN bus compared with its own - DSE-10 error (replace pendant)
IOs (active)
95 - - - -
96 Monitoring controller Error Monitoring controller has detected complete failure of main controller - DSE-10 error (replace pendant)
97 - - - -
98 - - - -
99 - - - -


Customer Support Info N - 01-2009: DEMAG Rope Hoist DR DR-Controller and DPC-Modul (Parallel-IN) and

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Customer Support Info N - 01-2009: DEMAG Rope Hoist DR DR-Controller and DPC-Modul (Parallel-IN) and

Enviado por

Direitos autorais:

Formatos disponíveis

Customer Support Info No.

090213-EN Dept.1922 - Product Support

0.3 DPC- Modul (Parallel-IN)

0.4 Pendant Control DSE internal DSE faults

Flash codes of monitoring controller (blue LED)

Horn sequences of DR without error codes

Error codes of radio receiver card

Flash codes of DRC-10 hand-held transmitter

Encoding of messages from DR control systems

Assignment of source of a message shown in the display for manual control

Assignment of messages to controllers of a DR control system

x01 to x63 Main controller HCS12

Flash codes of monitoring controller (blue LED )

Encoding of messages from DPC

Warning and error codes of the DPC module

Product Support Dept.1922

Product Support Dept.1922

Product Support Dept.1922

Flash codes of main controller (green LED, operating statuses)

Flash codes of monitoring controller (blue LED)

Encoding of messages from DSE-10

Warning and error codes of the DSE-10

Product Support Dept.1922

Message Source Type Description Possible malfunction / causes

Product Support Dept.1922

Message Source Type Description Possible malfunction / causes

Product Support Dept.1922

Você também pode gostar