Summary of Contents for Control Techniques Focus 3R
Page 1
Focus 3R ¼ to 5HP Single Phase Bi-Directional Regenerative DC Drive Page i...
Page 2
User Guide, without notice. All rights reserved. No parts of this User Guide may be reproduced or transmitted in any form or by any means, electrical or mechanical, without permission in writing from Control Techniques. Page ii...
Page 3
Whether it’s by phone, fax or modem, you can access Control Techniques support information 24 hours a day, seven days a week. Our wide range of services include: (716) 774-8327 You can FAX questions and comments to Control Techniques Just send a FAX to the number listed above. Website and Email www.emersonct.com...
Page 4
“Warning” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. “Caution” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. “Caution” used without the safety alert symbol indicates a potentially hazardous situation that, if not avoided, may result in property damage.
Page 5
Safety Considerations Safety Precautions This product is intended for professional incorporation into a complete system. If you install the product incorrectly, it may present a safety hazard. The product and system may use high voltages and currents, carry a high level of stored electrical energy, or are used to control mechanical equipment that can cause injury.
Page 6
General warning Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in this unit can cause severe electric shock and/or burns, and could be lethal. Extreme care is necessary at all times when working with or adjacent to this equipment.
Introduction This is the User’s Guide for Focus 3R (Regenerative) series of DC Drives. The Focus 3 is a 3rd generation product of the long-standing Focus series. The Focus 1 was introduced back in 1980 and the Focus 2 later in 1982. The Focus 2 was retired when the Focus 3 was introduced as it took advantage of many technological advances in power electronics.
3 requires 240vac input power and must be internally set for this input level. The motor field resistance should not be less than 150 ohms when cold and will require a series resistor to drop the additional field supply voltage. Consult Control Techniques Technical Support for additional information.
Page 12
Motors with: Permanent Magnet Motors typically have only 2 power wires. These are the Armature leads and typically designated A1 and A2 or A+ and A-. Armature Armature Voltage Current Page 6...
The DB option provides a rather quick stopping action and provides motor turning resistance when the drive is not in the RUN condition. The Focus 3R can be outfitted with a Dynamic Braking resistor should this requirement be desired. Note: DB Resistors require Contactor Option - See...
Page 14
General Information Introduction The purpose of this manual is to provide the user with the information needed to install, start-up, and maintain the Focus 3 drive. This instruction manual should be read in its entirety, paying special attention to the warning and caution notices, before installation and before performing any start-up or drive maintenance.
PERFORMANCE FEATURES • Solid State Full Wave Power Bridge -Uses generously rated power semiconductors for Maximum reliability and long life. • Four Quadrant Operation – The drive is capable of running in both the directions and providing full braking torque in both directions. •...
The Focus 3 comes in two basic model variations- with and without enclosure. Chassis Model The model without an enclosure is denoted as a chassis model. The chassis model is intended for mounting within a User supplied cabinet and where the User intends to provide remote Start/Stop and Speed control signals.
PERFORMANCE SPECIFICATIONS Service Factor Speed Regulation (95% Load Change): Armature Voltage 1% of Max. Speed with IR Compensation All other variables (voltage regulated) 15% of Base Speed Tachometer Feedback (DC) 0. 5% of Base Speed Speed Range: 30:1 Efficiency: Control Only Drive System (motor and control) 86% typically DRIVE OPERATING CONDITIONS Altitude (without derating)
OPERATOR FUNCTIONS Chassis Enclosed Speed Adjustment (Speed Pot) Standard Standard Start/Stop Customer Supplied Standard Auto/Manual Optional Optional Run/Jog Optional Optional Fwd/Rev Optional Optional CONTROL CIRCUIT SPECIFICATIONS Logic Control Power 24 Vdc Speed Potentiometer 5000 ohms Input Signal Requirement 10 Vdc @ 0.5mA Control Circuit Isolation Standard with regen F3R models Current Signal Follower...
Page 21
Focus 3 Chassis Dimensions Chassis Suitable for mounting in a user’s enclosure where internal temperatures will not exceed C or 130 SMALL REGEN & NON-REGEN MOUNTING 3.30" 9.75" 9.35" JP11 0.25" F3R2C 0.168" (4 PLACES) 6.36" 6.75" LARGE REGEN & NON-REGEN MOUNTING 4.50"...
Focus 3 Enclosed Dimensions NEMA 4/12 Suitable for most well ventilated factory areas where industrial equipment is installed. Locations subject to steam vapors, oil vapors, flammable or combustible vapors, chemical fumes, and corrosive gases or liquids should be avoided unless an appropriate enclosure has been supplied.
Page 23
Focus 3 Option Kits Focus 3 Enclosure Option – F3SE (small) up to 2HP F3LE (large) 3-5HP This kit provides the flexibility of stocking only Chassis drives and adding the enclosure when required. It reduces the number of stocked items to 6 (four chassis drives and two covers) as opposed to eight (four enclosed drives and four chassis drives).
Page 24
Focus 3 Option Kits Focus 3 Dynamic Braking Kit PN– See Table Below For use with Focus 3 Contactor Kits. Dynamic braking provides rapid motor stopping by quickly dissipating the stored energy in the rotating motor and load. These resistors have been sized in accordance with Nema specifications for dynamic braking.
Page 25
Focus 3 Option Kits Signal Isolator Board – P/N F3NSBD This option is used in applications where isolation is required between an external control signal and the motor controller (which may or may not be at earth ground potential). It can be utilized to isolate a variety of voltage or current signals (see specifications below).
Focus Family Options Speed Remote Operator Station – P/N 2950-9068 /2950-9066 Speed These NEMA 1 operator stations can be used to remotely control Focus 1 and Focus 3 Motor Controllers. Two models are available as shown. Both units include a Speed Start Potentiometer, a green normally open start button and a red Auto...
Page 27
Speed Potentiometer – P/N SpdPot This potentiometer can be used for either a remote speed command potentiometer remote current limit potentiometer. 120Vac Interface – P/N ACIF-2R-Focus – Run/Stop & Jog This kit is available for the Focus series of drives. It is designed to provide a 120-Vac interface for applications requiring remotely mounted industrial operator devices (i.e.
Customer Connections & Start-Up NOTE Read this manual in its entirety, paying particular attention to the Warnings and Cautions in each section before installing, starting, or maintaining this drive. Improper procedures can result in personal injury or equipment damage. Only qualified electrical maintenance technicians familiar with electronic drives and their standard safety precautions should be permitted to install, start-up, or maintain this apparatus.
Incoming Power Requirements A remote fused AC line disconnects or circuit breaker installed ahead of the control is required by the NEC (National Electrical Code). The control is designed to accept single-phase AC line voltage. Grounding The control must be connected to earth ground either via mounting screws provided by an enclosure or chassis-installed screw or by using the Earth Ground lug provided on the drive heatsink, for safety of operating personnel.
Page 30
Motor Thermal Switch For Motor Thermostat wiring, see the “Control Wiring” section. Wrong Motor Rotation If the motor rotates in the wrong direction, one of the following changes will correct it: Exchange Al and A2 output Motor Armature leads. Exchange Fl and F2 Motor Shunt field leads. If DC Tachometer Feedback is being used, Tach wires will also need to be swapped.
Drive Power Wiring ¼ - 2 HP Focus 3 Models F3R2E & F3R2C AC Line Earth Input Connection A+ & A- are the motor Armature leads F+ & F- are a shunt wound motors Field leads ( they will not be present on Permanent Magnet or Universal Motors ) Page 25...
Drive Power Wiring 3 - 5 HP Focus 3 Models F3N5E & F3N5C AC Line Input Earth Connection A+ & A- are the motor Armature leads F+ & F- are a shunt wound motors Field leads ( they will not be present on Permanent Magnet or Universal Motors ) Page 26...
Control Wiring TERMINAL CONNECTIONS (TB2) & DESCRIPTIONS Pin Number +24 Vdc Supply: Powers the logic inputs to the drive. It is not intended for it to be used to power external circuits. External use will void warranty. Tie Point: It has no internal connections and is used as a tie point for the Motor Thermal or Stop button connection.
Page 34
TERMINAL CONNECTIONS (TB2) & DESCRIPTIONS Drive Signal Common Connection: Drive circuit common connection. Minimum Speed Potentiometer Connection: This terminal is used in conjunction with the speed pot to provide a minimum speed setting. It is compatible with the Forward/Reverse switch option. Remote Current Limit Potentiometer: Wiper connection.
Control Wiring common, route wire away from high Entry current lines (i.e. AC lines and armature wiring). Recommended Cables and pots are available from : Control Techniques Service Center @ 1-800-367-8067 Page 29...
Page 36
Terminal Strip Connections Enclosed Model Standard Start / Stop & Speed Potentiometer Connections Motor Thermal or Jumper (customer supplied) Stop Start Drive will not start without this. This is intended for system interlock- see Application Safety The Start/Stop Switch And the Speed Potentiometer are supplied as shown on the drive cover...
Page 37
Optional Terminal Strip Connections Note: It is strongly recommended that all remote control connections to the drive (i.e. speed pot, start / stop etc.) are wired with shielded cable for noise immumity Two Wire ON / OFF with remote 0 to +10Vdc Speed command Jumper installed at factory Drive will not start without this.
Page 38
DC Tachometer Input With DC Tachometer Feedback Shielded cable should be 3 conductor with overall shield w/pot end tied off and dressed. Cable and pots are available from Control Techniques Service Center @ 1-800-367-8067 Cable P/N 3CONCBL-XXX (XXX in feet) Page 32...
Page 39
DC Tachometer Feedback DC Tachometer Input The Current Limit potentiometer is available from Control Techniques; see accessories section, page 20 Shielded cable should be 3 conductor with overall shield w/pot end tied off and dressed. Cable and pots are available from:...
Page 40
DC Tachometer Input DC Tachometer Feedback The Current Limit potentiometer is available from Control Techniques; see accessories section, page 20 Shielded cable should be 3 conductor with overall shield w/pot end tied off and dressed. Cable and pots are available from:...
CCW=counter clockwise Cable should be 3 conductor with overall shield w/pot end tied off and dressed. Cable and pots are available from: Control Techniques Service Center @ 1-800-367-8067 Cable P/N 3CONCBL-XXX (XXX in feet) Speed Potentiometer P/N SpdPot Page 35...
Customer Jumper Selections Jumper Programming Equipment damage and/or personal injury may result if jumper programming is attempted while control is operational. Always lock out power at the remote disconnect before changing jumper positions. See page 36 for jumper locations JUMPER DESCRIPTION RANGE FACTORY SETTING Optional “M”...
Page 43
Current Feedback Range (JP9) FOCUS Catalog DC Output Current Number (Amps) Jumper Position No Jumper (1/4 – 2 HP) F3R2C F3R2E No Jumper (3 – 5 HP) F3R5E F3N5E Current Control Mode Focus 3 Drives can be configured to operate in the Current Control Mode which is often referred to as making the drive a “Current Regulator”.
Page 44
Programming Jumper Locations IR Comp Optional Positive Motor Contactor Negative Control Connection Regulation Mode Speed / Current JP6 / JP7 Current JP10 Limit Pot 50 / 60 Hz Selection Operation Local or (in = 60Hz) Remote Armature/ Tachometer Tachometer Feedback Range Selector Armature...
Jumper Programming JP3-Tach Feedback Range - 6.5 to 17.4 Vdc - 60 to 160 Vdc JP11 ---- Input Voltage JP4 -------- Feedback Selector 120 Vac A to E Tachometer (Tach) & B to D Armature (Arm) 240 Vac A to C JP8 --------- Armature Voltage &...
Page 46
JP9 -- Max Output Current (100%) Removed - 2.7 A and less A – 5.5 A B – 6.4 A C – 7.5 A JP6 & JP7 --- Remote D – 10A Current Limit Pot Select Select based on Armature requirements Local –...
LED Status Indicators Current Limit LED – This red led will illuminate any time the run relay is energised Curr Lmt (Current Limit) – This yellow led will illuminate any time one of the three conditions are met: 1. The drive is at the maximum output current as set by the current limit potentiometer and the selected position of JP9...
Page 48
Internal Adjustments I Potentiometers Deceleration Acceleration Velocity Speed Stability Adjust Local Current Limit Minimum Speed Current Follower Gain Adj Maximum Speed Voltage Follower Gain Speed Rate Current Follower Zero Stability Bias Adjust (ISTB) Page 42...
Page 49
Basic Customer Adjustments Maximum Speed (MAX SPD) The MAX SPD pot sets the maximum motor speed (80-120% of motor base speed) allowed. It is factory preset to the midway position. Note: Do not exceed motor nameplate maximum speed rating. With the motor running, turn the speed pot on the drive enclosure cover/operator control panel fully clockwise while monitoring actual motor RPM or by measuring the Armature Voltage on A+ &...
Page 50
Acceleration and Deceleration Times (ACCEL / DECEL) The Focus 3 Regenerative DC Drive is a bi-directional drive, meaning that the drive can follow speed reference ranging from (+)10vdc (full speed forward) to 0 to (-)10vdc (full speed reverse). The acceleration and deceleration times are set by two potentiometers on the control board.
Basic Customer Adjustments Acceleration Deceleration Time adjustments SPEED Sets Jog Speed MIN SPD Adjust for minimum Motor speed MAX SPD Local Current Limit Limits maximum Output Current Adjust for maximum Motor speed Page 45...
Additional Tuning Adjustments Internal Resistance Compensation ( IR COMP ) Compensation pot is used to overcome the motor’s natural tendency to slow down as the load increases. If the motor slows down excessively as it is loaded, adjust the IR COMP pot clockwise to recover speed lost during the loaded condition. The motor will oscillate in speed or “hunt”...
Page 53
Additional Tuning Adjustments Velocity Stability IR Comp (VSTB) Adjust for speed loop Adjust for motor speed stability droop due to load Current Stability Speed Loop Offset (ISTB) Adjust for current Adjust for zero creep loop stability speed Page 47...
Page 54
Optional Tuning Adjustments Speed Rate Feedback (Spd Rate Fdb) Used with the VEL STAB pot, the SPD RATE FDB pot controls the relative magnitude of the “lead” circuit in the velocity loop. Clockwise rotation reduces the drive’s velocity rate of change and decreases the overshoot experienced by the drive. Normally used in tachometer feedback applications, this pot is factory set to its full counterclockwise position.
Page 55
Optional Tuning Adjustments Speed Current Speed Rate Zero Bias Reference Gain Reference Gain Page 49...
Start-up Guide Worksheet Improper procedures can result in personal injury or equipment damage. Only qualified electrical maintenance technicians familiar with electronic drives and their standard safety precautions should be permitted to install, start-up, or maintain this apparatus. At this point all INPUT POWER must be OFF ! Obtain the following information: Focus Drive Model F3R2C or...
Page 59
proper operation in the Speed mode, you could then switch over to Torque mode. Page 53...
Page 60
Focus 3 Jumper Setup Worksheet Refer to the data recorded on the previous page for this worksheet Refer to your motor nameplate data. STEP 1 Does your motor have a shunt field winding? If No go to STEP 5 otherwise go on. STEP 2 Is your motor field current greater than 1.1A? If No, go to STEP 3...
Page 61
Armature Current Programming - (JP9) Current Feedback Range STEP 7 Are you applying a Focus Model F3R2C or F3R2E ? If yes, then set jumper JP9 to the letter that matches up most closely with your motors Armature Amp rating from the table below: otherwise go to STEP 7a FOCUS Catalog...
Page 62
Application Safety When applying a motor drive in a manufacturing process, one must understand that the motor drive merely provides the energy for a motor to turn and it will do so without regard upon activation and command. There could be failure modes in any external interface equipment and/or the Focus drive itself that could cause the motor to turn suddenly at any speed or cause it to fail to stop on command without warning.
Initial Start-Up The following procedure is to verify proper operation of the drive in its simplest form as a basic speed regulator with no option kits installed. It is assumed that the drive is in its “out of box” condition with respect to jumper programming with the exception of what was just changed in the previous pages, jumper setup worksheet.
Page 64
Initial Start-Up con’t A minimal number of connections are made to the terminal strip (see diagrams below). If the drive is an enclosed unit with operator devices (start/stop and speed pot) only the jumper from terminal block TB2-1 to TB2-2 needs to be made.
Page 65
Initial Start-Up con’t 1. Adjust Current Limit Pot labeled LOC ILMT, fully counter-clockwise. Adjust Speed pot (enclosed unit) approximately 1/3 turn clockwise (from full CCW position) Adjust Jog pot (chassis unit) fully clockwise. Power can now be Applied ! 2. Start drive. Run light (red) and Current limit light (yellow) are illuminated. 3.
Page 66
Only do the next Step if the Drive is to be configuration as of Current or Torque Regulator. Otherwise Drive can now be set-up for terminal strip connections as required by the particular application. Refer to pages 30-32 for typical Terminal Strip Connections.
Focus 3 Trouble Shooting Guide IMPORTANT SAFEGUARDS All work on the drive should be performed by personnel familiar with it and its application. Before performing any maintenance or troubleshooting, read the instructions and consult the system diagrams. Only minor adjustments should be necessary on initial start-up, depending on the application.
Page 68
TROUBLESHOOTING OVERVIEW Fast and effective troubleshooting requires well-trained personnel supplied with the necessary test instruments as well as a sufficient stock of recommended spare parts. Capable electronic technicians who have received training in the control operation and who are familiar with the application are well qualified to service this equipment. Suggested Training A.
Page 69
BASIC TROUBLESHOOTING This paragraph contains a basic list of symptoms of an improperly functioning control. Included in the list are possible causes and corrective measures for each symptom described. BEFORE PROCEEDING WITH ANY MAINTENANCE OR TROUBLE-SHOOTING ACTIVITY, ALL POWER SOURCES MUST BE DISCONNECTED. CONTROL APPEARS TO BE DEAD Terminals TB2-1 and –2 on the main PC board not jumpered together - install either a jumper or the Motor Thermostat between these terminals.
Page 70
G. Motor brushes worn - replace as specified in motor instruction manual. Page 64...
Page 71
MOTOR RUNS IN WRONG DIRECTION: A. The Al and A2 output leads to the motor are incorrectly wired - exchange these leads. B. On shunt wound motors only the shunt field Fl and F2 leads are incorrectly wired – exchange these leads. MOTOR DOES NOT MAINTAIN SPEED UNDER LOAD: A.
Basic Test Setup – Light Bulb Test It is fairly easy to test Focus Drives on the bench. One does not have to use a motor to verify basic operation. When working properly, the Focus basically creates a variable voltage much like a light dimmer except the output is DC. The easiest way to check a Focus on the bench without a motor is to connect the Armature output to a resistive load.
Page 73
Record Drive Set-up BEFORE performing Light bulb test Before Test Test Circle One SPD CUR ARM TACH None 115 Vac 230 Vac 115 Vac Operation Operation Basic Armature Circuitry Checkout After the Focus is wired as shown on the previous page and the jumper set as indicated above, 115 Vac power could be applied and the Focus should cause the light bulb to vary in brightness from nothing to full brightness.
Page 74
Retrofitting Focus 2 Drives with Contactor Reversing with Focus 3 Regenerative Drives In retrofitting a Focus 2 with a Focus 3 drive there are four key issues to examine; physical size and mounting, location of power and signal connections, electrical compatibility and available options.
Page 75
Electrical Compatibility: The Focus 3 is electrically identical to the Focus 2 controller with the exception that the terminal strip connections are slightly different due to the addition of extra standard features. A comparison these two terminal strips are shown below. Focus 3 Focus 2 Motor Thermal...
Page 76
Available options: Focus 3 Focus 2 Jog at Jog Speed Standard Optional Current/Voltage follower Standard Optional Remote Current Limit Standard Optional Nema 4/12** Standard Optional AC Tach Feedback Optional Standard Reference Isolator Available Not Available Reversing Focus 3 Regen Drive Optional ** Enclosed Units Page 70...
Application Notes In order to provide continuing support for the Focus products (as well as all of our other products): ( if this is being viewed electronically, click on any blue item for link ) Application Notes (CTANXXX) Technical Notes (CTTNXXX) Replacement Instructions (CTRIXXX)
CTAN #130 Focus 3 Drives in Tachometer Follower Applications There are many applications that require a second drive to follow the speed of the first (or primary) drive. There are two basic methods used, the first is a parallel method and the second is a cascaded method. In the parallel method the speed command of the first drive is sent directly to the second drive (as a speed command) while in the cascaded method, the speed feedback (tachometer) is directed to the...
Page 79
Focus 3 Regen Master / Follower Application Motor Motor Armature Armature Motor Thermal Motor Thermal FOCUS 3 FOCUS 3 Stop Stop Start Start Drive run enable Drive run enable Motor Field Motor Field Regen Regen Manual only Manual only Auto Auto Speed Speed...
Need help?
Do you have a question about the Focus 3R and is the answer not in the manual?
Questions and answers