EZDR 5 & 10 EKDR 3, 5 & 10

FDR 3, 5 & 10

EZDR 20 FDR 20
Table of Contents

Error Code 3 ---------------------------------------------------------------------------------------------------------- Page 3

Error Code 17 -------------------------------------------------------------------------------------------------------- Page 4
Error Code 21 -------------------------------------------------------------------------------------------------------- Page 6
Error Code 31 -------------------------------------------------------------------------------------------------------- Page 8
Error Code 36 -------------------------------------------------------------------------------------------------------- Page 9
Error Code 38 -------------------------------------------------------------------------------------------------------- Page 10
Error Code 63 -------------------------------------------------------------------------------------------------------- Page 11
Error Code 78 -------------------------------------------------------------------------------------------------------- Page 10
Error Code 140 ------------------------------------------------------------------------------------------------------- Page 12
Error Code 179 ------------------------------------------------------------------------------------------------------- Page 12
Green LED Flashes 6 Times---------------------------------------------------------------------------------------- Page 13
Green LED Flashes 8 Times---------------------------------------------------------------------------------------- Page 14
Horn Signal 1x Long, 2x Short------------------------------------------------------------------------------------ Page 15
Lifting is Intermittent & Slow------------------------------------------------------------------------------------- Page 16
Hoist Unit Moving Slowly in Both Directions & Has Limited Operation ------------------------------- Page 17
Installation Stand Still ---------------------------------------------------------------------------------------------- Page 18
Reference Documents --------------------------------------------------------------------------------------------- Page 20
 Error Code 3
Error Code 3
K1 shows unexpected behavior
(does not pick up or drop,
generation of control voltage,
feedback contact)

Control Voltage = 48 VAC

Control Voltage Transformer

Line Voltage Input Connection

380W -20V / 400W

Control Voltage Ok? 380W +10 +20V/ 400W
Control Voltage Check primary connection- 380W -10 0/ 340W
should be 47-50 VAC Control voltage between
*see list to right & 47-50 volts
400W 0/ 400W

P001. 400W +10 -20B/ 460W

400W -10 +20V / 340W

415W +20V/ 400W

415W +10 0/ 460W

415W -10 +20V/ 400W

K1 wiring on coil A1
& A2, contact 21 & Connect the wires 440W -20V/ 400W

22 respectively? correctly or repair 440W +10 +20V/ 460W

440W -10 0/ 400W

460W 0/ 460W

460W +10 0/ 500W

460W -10 +20V/ 400W

K1 Ok? 480W +20V/ 460W
Check K1. 480W +20V/ 460W
Electrical/ Change K1 480W +10 +20V/ 500W
mechanical
480W -10 -20/ 460W
*see D001

Control Voltage Transformer

Factory Settings- DR

Line Voltage Input Connection

Change DR-single 380W 0 / 400W
board or ISS/HSS
400W +20V/ 400W
module (modular
415W -20V/ 460W
electric)
440W 0/ 460W

460W +20B/ 460W

Function OK 480W 0 / 500W
Page 3

©2020 Demag Cranes & Components Corp

 Error Code 17
Error Code 17
Evaluation rotary encoder lifting:
Setpoint value available, but axis
at standstill.

Does the motor Are all 3 phases leading

1
start to the motor?

2
External pulse
generator?
3

Check the
mechanical Adjust mounting of the
mounting, pulse generator.
arrangement, & *See D006.
coupling

Check the
encoder plug, Repair or change the
plug on control defective supply and/or
board & plug.
connection cable

Change the pulse

generator

Does the error Repair or change the 4

still exist? defective supply and/or
plug.

Page 4
©2020 Demag Cranes & Components Corp
 Error Code 17
Check the wiring.
Repair if necessary Does the error
or change the still exist?
cables.

Check contractor
1 K1. Change Contractor
K1
*See D001.

Change ISS-module
Does the brake (modular electric)
2 lining stick on the or the complete
end shield (b-side)? control board
(single board)
3
Check the motor
winding. Change
motor if necessary.
Check the power Clean the brake lining.
supply control Loosen the brake lining
board <---> from the end shield,
Interface IMP <---> changing the brake if
rotary encoder needed.
Repair or change
connection cables.

Change rotary Does the error

encoder interface still exist?
IMP.

Dismantle end shield Check if pulse wheel

(b-side), check EG is damaged. Change
(photo cell). Clean if pulse wheel or photo
necessary. cell if necessary.

4 Function OK

Page 5
 Error Code 21
Error Code 21
Trolley inverter doesn’t signal to be ready.
Possible cause: Thermo contact.

Change DR Control
Does the lifting axis
Board
work?
1
Internal hardware
error of DR control
board

Is the red LED at the

trolley inverter on?
Wait for trolley
inverter run-up time Is the green LED at
(approx. 5 seconds) the trolley inverter 2
flashing?

Check the control

Check the thermo cable between F1 & 3
contact & power DR control.
supply. *See P003

4
Check the motor
winding & power Check the thermo
supply. *See P012 contact. 5
*See P002

Check the motor

Use Parcom winding.
Contact of KP 500 *See D017
for fault analysis.
Change trolley
motor

F1 error
*See D111
Function OK

6
7
Page 6
©2020 Demag Cranes & Components Corp
 Error Code 21

Switch on the
1 circuit breaker.

Is L1 – L2 – L3 at Check the power

2 trolley F1 available? supply to the control
*See P008 board F1.

Change the cable.

Change the
3 control cable.
Change the F1
control board.

Change DR control
4 board.. Change the trolley
inverter.
5

Change the power

supply.

6
7 Function OK
Page 7
 Error Code 31
Error Code 31
Monitoring contact of hoist
brake signals an improper brake
release

Clean and adjust the brake.

Brake setting ok? *See D008. See settings in
the operator manual.

Adjust or change the micro

Microswitch ok? switch.
*See D007

Change the DR control

board.

Function OK

Page 8
©2020 Demag Cranes & Components Corp
 Error Code 36
Error Code 36
Monitoring contact of hoist
brake signals that brake cannot
be released.

Switch on the circuit

Is the circuit breaker switched?
breaker

Is the brake adjustment ok? Adjust the brake.

Is the micro switch ok? Adjust the micro switch.

*See D007.

Is the brake coil ok? Change the brake coil.

Is the cable assembly ok? Change the cables.

Change the DR control

board.

Function OK
Page 9
©2020 Demag Cranes & Components Corp
 Error Code 38 & 78
Error Code 38 Error Code 78
Evaluation rotary encoder lifting:
Direction of revolution error
setpoint value available & axis
lifting.
moves in wrong direction.

Does the hoist move

in the correct
direction?
Change 2 phases.
From SW V.3xx Is the phase sequence
onward, the ok?
control voltage
must be switched
off to eliminate Change ISS module,
the error. single board electric or
direction relay (HSS
control).

Check the wiring

between the DR Change the
electric & pulse defective cables
generator.

Check the internal Change the

pulse generator. internal pulse
generator.

Change the EGS-2

module.
Change DR
control board.

Function OK
Page 10
©2020 Demag Cranes & Components Corp
 Error Code 63
Error Code 63
Warning “Inverter not available yet.” Moving in selected
direction not possible due to hoist inverter parameters either
have not been read or are not correctly programmed.

Does the warning only

show after switched
on?

Is one of the hoist

F1 LEDs on?

Are L1-L2-L3
available at hoist Check the power
F1? supply.

Does the hoist work Replace the

with warning 63? hoist F1.

Check the CAN-Bus

connection hoist F1. Replace or repair
*Connect a serial cable the cable.
for testing.

Warning disappears itself-

Wait for run-up time
(approx.. 1:45 minutes).
Do not use the controls Change CAN-Bus
during this time. module..

Parameter 830 active

load spectrum
calculation.

Function OK
Page 11
©2020 Demag Cranes & Components Corp
 Error Code 140 & 179
Error Code 140 Error Code 179
OK of min. one trolley for OK of min. one trolley for
switching the crane contactor on switching the crane contactor on
via CAN-Bus missing. via CAN-Bus missing.

Are there any other

error messages?

Check the CAN-Bus

writing between KRBG Change 2 phases.
& trolley board.

Resolve all other Does the Green LED

Green LED
problems/ faults before from the trolley
flashes 6 times.
proceeding. control board flash 8
**See page X.
times?

Replace the DR control

board on the trolley.

Function OK
Page 12
©2020 Demag Cranes & Components Corp
 Green LED Flashes 6 Times
Green LED Flashes 6x

Did the error occur Download the Try to upload the

after the replacement parameters using complete parameter
of the control board? proprietary IDAPSY set immediately after
software, the download.

**Switch off the

control voltage!!
Is the EEprom plugged Plug the EEprom from
in? the old control board
to the new board.

Is the software Convert the parameter data

version of the old after replacing the control
control board higher board & EEprom.
than v1.99? *See D010.

Check if the EEprom is damaged

(e.g. broken pins). Replace if
necessary.

Function OK
Page 13
©2020 Demag Cranes & Components Corp
 Green LED Flashes 8 Times
Green LED Flashes 8x

Do the green LEDs

flash on all boards 8 *See D012.
times?

Check the terminating Correct the

resistors. adjustment of the
*See D011 terminating resistors.

Check the CAN-Bus Adjust the DIL switch.

wiring.

Check the “DIL” switch

(CAN-Bus addresses). Repair it.

Read CAN-Bus subscriber with

CAN-monitor out & change Function OK
defective subscriber using
proprietary IDAPSY software.

Page 14
©2020 Demag Cranes & Components Corp
 Horn Signal 1x Long, 2x Short
Horn Signal- 1 time long, 2 times short
Number of safety relevant control signals has exceeded the
limit with CAN-Bus not active- SRDO error

Are the DSE & radio Disconnect the DSE

remote plugged in? or radio remote.

Is the DSE CAN Are there messages in Check the

available? the display? control cable
and plug of DSE Replace CAN-Bus
by connecting training cable or
the pendant control cable
directly to the DSE.
KRBG.

Do the green LEDs

flash on the board 8 Replace the DSE.
times? *See D012

Check the terminating

resistors. Set the terminating
*See D011 resistors correctly.

Check the DIL switch

Set the DIL switches.
(CAN-Bus addresses)

Check the CAN-Bus

wiring. Repair it.

Read the CAN-Bus subscriber with

CAN monitor out & change
defective subscriber using
proprietary IDAPSY software

Page 15 Function OK
©2020 Demag Cranes & Components Corp
Lifting is Intermittent & Slow

Intermittent & Slow

Lifting

Does the error only

occurring after lifting
the load?

Using proprietary
IDAPSY software,
Using proprietary observe the control
IDAPSY software, adjust commands with CAN
code 304 or creep speed monitor. Review
time. *Time must control place if
exceed zero. necessary.
*See D016.

Function OK

Page 16
©2020 Demag Cranes & Components Corp
 Hoist Unit is Moving Slowly in Both Directions
& Has Limited Operation
Hoist is moving slowly in
both directions & has
limited operation.

Is the display available?

Is the red LED

permanently on? (from
hardware 700 onward)

Is the maintenance
symbol showing in the
display?

Is the travelling
command V2 active?
*Must use proprietary
IDAPSY software.
Overhaul the brake Not possible.
using proprietary
IDAPSY software.
Parameter E_141_02
measured braking
distance >300
*See D016. Change the DPC module.

Function OK

Page 17
©2020 Demag Cranes & Components Corp
 Installation at a Standstill (pg. 1 of 2)
Main voltage Main switch turned Turn main switch
available? on? on.

Check fuses and

power lines.

Are the green LEDs Will the relay be

Is CAN monitoring Check the device
Error Code number? flashing more than 1 DSE pendant/ Radio? DPC? triggered? (Parallel-
available? control.
time? IN)

Consult errors with

Consult CAN monitor Consult flash codes in Check error history in
Radio Remote? DPC in IDAPSY
Check error in IDAPSY software. IDAPSY software. IDAPSY software.
software.
messages.

When in emergency
stop, is there Stop in
the display as well?

DSE self test ok?

Change DSE Function
Radio contact Consult IDAPSY
pendant. OK
available? software.

Not
Possible
Receiver card and
antenna ok? Consult
something
Not
Possible

DRC self-test ok?

Change DSE
Consult IDAPSY
transmitter.
software.

Not Possible.
Page 18 ©2020 Demag Cranes & Components Corp
 Installation at a Standstill (pg. 2 of 2)

Control voltage
available? Change the control
transmitter.

Control transmitter
ok?

Check wiring and

X27

Plug in connection ok? Repair or fasten

plug-in connections.

Change pendant or
supply.

Function
OK

Page 19 ©2020 Demag Cranes & Components Corp

Reference Documents

D001 -------------------------------------------------------------------------------------------------------------------- Page 21

D006 -------------------------------------------------------------------------------------------------------------------- Page 23
D007 -------------------------------------------------------------------------------------------------------------------- Page 28
D008 -------------------------------------------------------------------------------------------------------------------- Page 30
D010 -------------------------------------------------------------------------------------------------------------------- Page 34
D011 -------------------------------------------------------------------------------------------------------------------- Page 37
D012 -------------------------------------------------------------------------------------------------------------------- Page 40
D016 -------------------------------------------------------------------------------------------------------------------- Page 41
D017 -------------------------------------------------------------------------------------------------------------------- Page 43
D111 -------------------------------------------------------------------------------------------------------------------- Page 44
P001 -------------------------------------------------------------------------------------------------------------------- Page 47
P002 -------------------------------------------------------------------------------------------------------------------- Page 48
P003 -------------------------------------------------------------------------------------------------------------------- Page 49
P008 -------------------------------------------------------------------------------------------------------------------- Page 50
P012 -------------------------------------------------------------------------------------------------------------------- Page 51

Page 20
 D 001

Page 21
D 001

Page 22
 D 006

Page 23
D 006

Page 24
 D 006

Page 25
D 006

Page 26
 D 006

Page 27
D 007

Page 28
 D 007

Page 29
D 008

Page 30
 D 008

Page 31
D 008

Page 32
 D 008

Page 33
D 010

Page 34
 D 010

Page 35
D 010

Page 36
 D 011

Page 37
D 011

Page 38
 D 011

Page 39
D 012

Page 40
 D 016

Page 41
D 016

Page 42
 D 017

Page 43
D 111

Page 44
 D 111

Page 45
D 111

Page 46
 P 001

Page 47
P 002

Page 48
 P 003

Page 49
P 008

Page 50
 P 012

Page 51
©2020 Demag Cranes & Components Corp