Deutsche GROVE

Home page

GMK 5100
EKS 4
Simulation

Dieter Roben
 Deutsche GROVE

EKS 4

Simulation
1. System requirements ........................................................................................................... 1
2. Starting the program ..................................................................................................................1
2.1 Program entry window ........................................................................................................................ 2
2.2 Program window.................................................................................................................................. 3
2.3 Acknowledgement / configuration entry ............................................................................................. 4
2.4 Outputs / inputs & sensor controls....................................................................................................... 5
2.5 Error codes .......................................................................................................................................... 6
2.6 Sensor inputs ....................................................................................................................................... 7
2.7 Sensor operation .................................................................................................................................. 8
2.7.1 Table 1: Boom length status ........................................................................................................ 9
2.7.2 Table 2: Multilevel inputs............................................................................................................ 9
2.7.3 Table 3: Relay interface............................................................................................................. 10
3. Extending the boom ..................................................................................................................11
4. Load capacity charts & info ............................................................................................. 13
RC. September. 2000

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000

 Deutsche GROVE

1. System requirements
The EKS 4 Software Simulation program can be installed on A PC with the following system
requirements:
• Pentium processor
• Windows 95/98
• 256 Colour graphics card
• Monitor display of 800 x 600

2. Starting the program

To start the program, choose Simu5100V1002S4 for (Metric- DIN) and double-click the icon
arrow on the desktop shortcut (fig.1) or select Programs (fig.2) and then select
Simu5100V1002S3 for DIN ratings (fig.3) from the program list. The other two remaining
programs are 2002S3 for the USA and 3002S3 for 85% DIN.

Metric

Simu5100
V1002S4

Figure: 1

Figure: 2

Figure: 3

This will then bring up the following window:

GMK 5100 Training Information. EKS 4 Simulation DIN. September. 2000 1

 Deutsche GROVE

2.1 Program entry window

Two language options are available: German or English.

1. Click on the North America icon to select English language.

2. Click on the start button to activate the program

Figure 4: Program entry window

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 2

 Deutsche GROVE

2.2 Program window

An interactive window is displayed with interactive controls, which allow functional control
of EKS 4 and manipulation of the inputs via external sensors.
The window is split into two main control/display areas. On the left is the central unit with
very similar controls to the actual in-cab unit. On the right is the relay status display,
multilevel input display and telescope status display with input switches to the left and right,
followed by a lower dialog box with six tab headings.

Figure 5: Typical view of interactive window display on startup.

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 3

 Deutsche GROVE

2.3 Acknowledgement / configuration entry

Acknowledgement of current status or any changes to the crane configuration must be entered
on starting the system.

The central unit functions remain the same

as the in-cab unit.
On starting the program it is necessary to
acknowledge the current status or enter a
new configuration status prior to the sensors
having full operational abilities.
Without acknowledgement/new entry an
error code will be displayed and the output
relays will remain de-energised (fig.7).
Entering the reeving mode covers:
• Parts of line
Entering the operating mode covers:
• Outrigger spread
• Installed counterweight
• Operating arc
• Length of lattice extension
See Operator’s manual and capacity chart
manual for correct entry details.

Figure 6: Central unit control functions

The yellow field in the bottom fight of the window shows the current error status.

Figure 7: Output relay status in motion cut

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 4

 Deutsche GROVE

2.4 Outputs / inputs & sensor controls

Relays: represents the function of the internal relays that are switched by the program to
control the indicated crane functions. The relay contact connections are via the crane’s
electrical interface. See table 3.
Multilevel inputs: shows a visual indication when a digital input is active. The numeric
reference and description can be found in table 2.
Control switches: allow mouse click control of the indicated functions.
Heading tabs: show the six possible sub-window display fields.
Telescope status: indicates the current position of the telescope cylinder.

Relays
There are 12 internal relays controlled by EKS 4
that have output control functions. Red indicates
that the relay is de-energised

Multilevel inputs
There are 24 possible inputs, in this application
only 8 are used to confirm the digital input from
proximity switches etc. The silver background
indicates the respective input is active.

Control switches
Switches write-protect, external bridge, locked
tele cyl & locked boom pin. A silver background
indicates the function is active. Write protect is
only used for programming.

Heading tabs
Six sub-windows can be selected with the heading
tabs. Only ‘sensors’ & ‘error messages’ have any
relevant simulation functions.

Telescope status
The numeric background will flash to indicate
that the telescope cylinder is in the correct pinning
position within the base of each section.

Figure 8: Inputs & sensor controls

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 5

 Deutsche GROVE

2.5 Error codes

Should it be necessary to investigate the cause of an error code, clicking on the error message
tab will allow you to see the displayed code. Directly below the code is the error group
description (operation) with the cause of the error (Input of rigging / reeving code) displayed
to the right.
The lower field suggests the corrective action to be taken. It is possible to navigate the group
codes with the navigation arrows below the dialogue box.

Figure 9: Error messages

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 6

 Deutsche GROVE

2.6 Sensor inputs

With the reeving & operational modes acknowledged and the correct multilevel inputs all the
functional output relays will be (green) energised, allowing manual simulation with the
horizontal sliders on the sensor tab, which has also been selected.
The relay outputs for ‘Derrick in swing-away lattice’ & ‘Derrick out swing-away lattice’ will
remain (red) de-energised, as they have no current function.
Note: the external bridge (RCI bypass) must be de-selected to prevent an error code display.

Bus-node digital values

Figure 10: Fully operational simulation window

To have an operational system the Bus- Telescope cylinder = 1044 – 3500

node digital values must remain within Main boom angle = 1250 – 4500
Pressure, piston side = 1150 – 5120
the indicated parameters on the right. Pressure, rod side = 1024 – 5120

See EEPROM 1 list for Bus-node digital value parameters.

Practice with the sensors: main boom angle and Pressure, piston side.

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 7

 Deutsche GROVE

2.7 Sensor operation

As the simulation system has no induced pressure from the boom it will be necessary to keep
the piston side pressure above the indicated threshold levels to prevent negative hook weight.
The rod side sensors should be set to just above threshold (1050) and left there!
To practice extending the boom it is recommended to select 4 parts of line with a large
counterweight and elevate the boom to an angle of 800. This will give you acceptable
tolerance to extend/retract the boom without readjusting the load on hook value.

Figure 11: Unlocked telescope cylinder

Unlock the telescope cylinder by clicking on the ‘locked tele cyl’ button and then extend the
telescope cylinder within the base of each section 1 – 4. Click on the arrows to the left & right
of the telescope slider for fine control or click on the light grey background of the slider for
rapid movement of the cylinder. See table 1 for length % info.
The % length of telescope cylinder is shown to the right of the sensor. Holding the mouse in
the grey background should also prompt a cylinder % length display. Observe the telescope
status ‘in-position flashing’ and the multilevel inputs while doing this.
Once the telescope cylinder is unlocked and moved from the current ‘in-position’ the ‘locked
boom pin’ function will be greyed out as it is not possible to operate the boom pins without
being ‘in-position’. It is also not possible to unlock the telescope cylinder and the boom
section pins together.

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 8

 Deutsche GROVE

2.7.1 Table 1: Boom length status

The following table gives an approximate guide to the cylinder % length relative to the boom
section pinning positions:
Table 1

Boom length status

Boom Approximate telescope cylinder % length for indicated
section Boom length
1 0 = 0% 0.5 = 45% 1.0 = 91%
2 0 = 3% 0.5 = 48% 1.0 = 94%
3 0 = 6% 0.5 = 51% 1.0 = 97%
4 0 = 9% 0.5 = 54% 1.0 = 100%

2.7.2 Table 2: Multilevel inputs

The following table identifies the multilevel digital inputs that are relevant to simulation:
Table 2
Contact Type Plug/pin Dual Function description Connection
ID reference connection with signal voltage
with ext bridge

Input 1 Dual X3.1 No Recognition of telescope HS_2000R

cylinder locking point A
Input 11 Dual X3.3 No Recognition of telescope HS_2000R
cylinder locking point B

Input 5 Dual X3.13 No Main hoist enabled Without RB

Input 7 Dual X3.15 No Auxiliary hoist enabled Without RB

Input 12 Dual X4.1 No Boom section pins locked HS_2000R

Input 13 Dual X4.4 No Left telescope cylinder pin HS_2000R

locked

Input 14 Dual X4.7 No Right telescope cylinder HS_2000R

pin locked

Input 17 Mon X4.14 By-pass RCI Without RB

o

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 9

 Deutsche GROVE

2.7.3 Table 3: Relay interface

The following table identifies the electrical interface connections for the internal micro relays.
Table 3
Name Type Pin reference EKS-4 ZE Meaning
N/O Common N/C When de-energised the description is
contact contact valid

K1 N/O X1,3 X1,2 - RCI (SLI) error

contact
K2 N/O X1,6 X1,4 - Display shutdown (motion cut)
contact
K3 N/O X1,9 X1,7 - Switch off main hoist raise
contact
K4 N/O X1,12 X1,10 - Switch off derricking down
contact
K5 N/O X1,15 X1,13 - Switch off telescoping extending
contact
K6 N/O X2,3 X2,1 - Switch off auxiliary hoist raise
contact
K7 N/O X2,6 X2,4 - Switch off derricking up
contact
K8 N/O X2,9 X2,7 - Switch off telescope retracting
contact
K9 N/O X2,12 X2,10 - Switch off auxiliary hoist lower
contact
K10 N/O X2,15 X2,13 -
contact
K11 CO X1,11 X1,8 X1,14 Pre-warning display
contact
K12 CO X2,11 X2,8 X2,14
contact

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 10

 Deutsche GROVE

3. Extending the boom

1. To extend the boom, enter a reeving mode input of 4 parts of line and an operational mode
of 710, raise the boom angle to 800 and apply a hook load of 5t.

Figure 12: Example of crane configuration prior to extending the boom

2. Unlock the telescope cylinder, extend it into boom section 4, and lock it to that section as
shown in Fig.11.
3. Click on the locked boom pin button to unlock the boom section pins. The ‘locked tele
cyl’ button will automatically be greyed out.
4. The boom length status will now only show single digits.
5. Use the telescope sensor to extend the boom section, you will notice that the ‘locked boom
pin’ button will be greyed out when you leave the pinning position and will re-activate on
approach to the 50% (0.5) position. Keep extending the boom section to 100% (1.0), it
will then flash as 1.0. Be careful not to overrun this position, as motion cut will occur
once you exceed the program parameters on the bus-nodes!
6. Should this occur, click on the ‘external bridge’ (RCI bypass) to allow you to retract the
boom section and then release the ‘external bridge’ and press CE to begin operation again.

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 11

 Deutsche GROVE

7. Lock the boom section at (1.0.) by clicking on the locked boom pin button, which is now
active, this will cause the boom length status display to change to (1.0.0).
8. Unlock the telescope cylinder and retract it to begin the cycle again, but now selecting and
locking to boom section number 3 prior to fully extending it.

Figure 13: Boom section number 4 locked at 1 0 0 and cylinder positioned in boom section number 3.

9. Continue the extension sequences until the boom is fully extended, taking care to overrun
the pinning positions in table 1.

Figure 14: Fully extended boom status display

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 12

 Deutsche GROVE

4. Load capacity charts & info

Right clicking on the active window will bring up a sub-menu with the following menu
selections:

Figure 15: Menu

Dragging a box around a reference point with the mouse will produce a chart with greater
incremental detail of the load (Last) & radius (Ausladung) for the current configuration.

Figure 16: Load capacity chart display

Figure 16a: Detail load capacity chart display

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 13

 Deutsche GROVE

The pinning positions represent the target positions in % & length of the telescope cylinder.

Figure 17: Pinning position information

Figure 18: Information

GMK 5100 Training Information. EKS 4 Simulation. DIN. September. 2000 14