By Rebecca Hart, Marketing Manager and Greg Ostrowski, Engineering Manager

We all know that electronic controls may not work from time to time. If we’re lucky, we will install a control and never have to call for repair. There are times when a little troubleshooting will go a long way. If you know what to do, you won’t have to make a service call.

Our EC-2000 is our newest control that functions not only with Dynamatic® brand products, but many other brands as well. If you run into a problem, it’s best to start at the control to see if the problem can be fixed there.

Here, we provide you with a step-by-step guide to troubleshoot your EC-2000 control.

Troubleshooting Your EC-2000 Control

If the control will not “run” or “start” in remote mode

  • Verify there is a normally closed button or jumper between TB2-22, TB2-23, and TB2-24, that man-auto start source is set to Term. and that The PLC Run parameter is disabled under source menu.
  • Double check your control modes such as “LOCAL” and “REMOTE”. Need to be in remote mode.
  • Check the “MENU K: SOURCE SELECT” to make sure the proper start sources are programmed. If you are starting the control with terminals.  Set Auto Start Source & Manual Start Source to Terminal.  If using serial mode or keypad, set to Start Source to keypad or Serial.

If the Drive does not Run once enabled

  • Verify you have a setpoint programmed. The setpoint is the top right line of the display.
  • Verify the control says “RUN” on the top left line of the keypad. If it says “RUN0”, then there is no set point reference.
  • If in Manual Remote mode check Preset1 Set point under Source Menu. Needs to set to term or pulse depending on set point source.  If in auto mode check Auto Set point SRC.  Needs to be term for terminal and serial for serial or keypad.
  • Disconnect the clutch coil leads from the EC 2000 (C1 and C2). Try to run the control with a setpoint and measure the DC voltage on the TB1-C1 and C2 (where the clutch coil leads were just connected). A high DC voltage should be obtained (over 90VDC). If not, contact Dynamatic for a replacement board. If there is a voltage on those terminals, measure the resistance of the clutch coil and compare to the value on the drive nameplate as it could be a defective clutch coil or slip ring issues.
  • If there is no DC Output, check if Jumpers 11 and 13 are in the “A” position on the circuit board for standard control, B for high power control.

If the drive is running at full speed

  • Determine if the control is utilizing the tachometer or pulse pickup input and if the Jumper J4 is set correctly. A for pulse pickup, B for Tachometer.
  • If Tachometer is used measure the AC Tachometer Voltage on TB1-G1 and G2 while the unit is running at full speed. One should see a voltage anywhere from 30VAC to 60VAC. If no voltage is measured, verify that the drive is running. You may need to replace the AC Tachometer Generator inside the drive. If an AC voltage is indeed measured, check the mechanical unit to see if there is a lockup between the drum and rotor. If your clutch rotates at full speed without the control being in “RUN” mode, then there is a lockup between the motor and the clutch.
  • If the pulse pickup is used, while the unit is running at full speed, check the voltage on TB2-1 And TB2-2. Should read 6 to 7 VAC.
  • Verify the “TACH PULSES/REV” setting in MENU A is correct.

If fuses blow

  • Verify the EC 2000 is not underrated for the mechanical unit.
  • Verify the right voltage is being applied at TB1-L1 and L2 (115VAC).
  • Check to see if the clutch coil or brake coil is shorted.
  • Verify incoming power is properly grounded.
  • Disconnect the clutch and brake leads and try to power the control. If the fuses blow again, the EC 2000 needs to be replaced if incoming power is measured to be proper.

Cannot change any settings

  • Press F1, F2, and F3 on the keypad successively to unlock the keypad for access.
  • Try resetting the EC 2000 by pressing “SW1” button on the 15-1200-1 board or by removing all TB2 wires and placing a jumper between TB2-32 and TB2-29, then applying power.

Follower or potentiometer signal not changing setpoint

  • Verify the control is in the right mode. “AUTO” mode corresponds to an automatic follower signal. “REMOTE” mode corresponds to a signal that is external to the keypad.
  • Check to see if any external connections into TB2 are improperly grounded. Recheck the wiring diagrams seen in Figures 8 through 13. If multiple signals are wired into TB2, try disconnecting signals one by one to eliminate possible issues.
  • Verify the signals are present at TB2.
  • If the control is in the proximity or powered by a large transformer that causes a surge during power up, set a startup delay in the control setup menu. 1 second is enough.
  • Reset the control to factory defaults and try again. A programming error can cause this problem.

Unstable speed

  • Adjust the PID loop parameters in Clutch Performance – Menu B.
  • Check the speed display. If the speed feedback is erratic, set a speed clamp # and value under Menu A Control Setup.  See parameter listing for info.

Speed display is different than actual speed

  • Verify that the Tach Pulses/REV setting in Menu A, Parameter 5 matches your mechanical unit. If unknown, try another setting and see if the displayed speed is closer to the actual speed. Adjust the clutch PPR scale factor to display correct speed if need be.

Screen is frozen and/or has unfamiliar content

  • Try resetting the EC 2000 either by pushing “SW1” on the 15-1200-1 board or by removing the e-stop connection 31 to 32, the stop connection 24 to 22 and place a jumper between TB2-32 and TB2-29. This will reset the control to factory defaults.

Screen is lit, but nothing is displayed

  • Try resetting the EC 2000. If the issues persist, check to see if the keypad cable is inserted correctly or not damaged.

Local/remote key does not work

  • Check to see if “LOCAL/REM ENABLE” is enabled in Menu A, Parameter 12.

Drive is slower than desired

  • Check to see if the clutch current limits are properly set in Menu A, Parameter 4.
  • Verify the control is not in torque limit.  Torque-Lim will appear at the top of the display.  Verify the pulse parameter and scale factor are correct.

Once you have exhausted all measures to troubleshoot your EC-2000 and if you are still experiencing problems, a Dynamatic engineer will help diagnose the issues and repair as needed. Give us a call at (262) 548-2169.