General Information The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent or incorrect installation or adjustment of the optional operating parameters of the equipment or from mismatching the variable speed drive with the motor. The contents of this User Guide are believed to be correct at the time of printing. In the interests of a commitment to a policy of continuous development and improvement, the manufacturer reserves the right to change the specifications of the product or its performance, or the contents of the User Guide, without notice.
Customer Support Control Techniques 359 Lang Boulevard, Building B Grand Island, New York 14072 U.S.A. Telephone: (716) 774-1193 It is Control Techniques’ goal to ensure your greatest possible satisfaction with the operation of our products. We are dedicated to providing fast, friendly, and accurate assistance.
“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.
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.
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.
Table of Contents Topic Page Introduction Motor Compatibility Eddy Current Clutch Control Basic Control Modes/Feedback Armature Voltage Feedback Speed or Tach Feedback Quick Stops Receiving, Inspection, Storing Performance Features Nameplate Information Nameplate Location Catalog Number Definition Specifications Ratings Table Performance Specifications Operating Conditions Internal Adjustments (Potentiometer) Customer Selections (Jumpers)
Table of Contents Topic Page Power Wiring 24-25 Control Wiring 26-33 Speed Pot Wiring Customer Selections Jumper Programming 34-38 Current Ranges Current/Torque Control LED Status Indicators Potentiometer Adjustments 40-46 41-42 Basic Adjustments 43-44 Tuning Adjustments Interconnect Drawings Functional Block Diagram Non-Regen Circuit Overview Start-up Guide Worksheet 49-51...
Introduction This is the User’s Guide for Focus 3N (Non-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.
Motor Compatibility The Focus 3 was designed to run standard 90 Vdc or 180 Vdc Shunt Wound or Permanent Magnet DC motors in one direction. The Focus 3 can run motors with other characteristics (such as Universal motors) but one must review those requirements to insure compatibility. Universal motors have commutator brushes but typically plug into the AC power line.
This current level can be “fine tuned” to the exact coil current of the clutch being controlled. For more specific information, refer to CTAN213 via the Internet at our website: www.emersonct.com or click the link below: CTAN213 Emerson Eddy Control Techniques WER Eddy Current 1235 Focus Eddy Current Current 367...
Speed Control Armature Voltage Feedback The Focus 3 can vary the speed of the motors mentioned above as a function of the Speed potentiometer setting (or external speed command signal) by simply varying the output Armature voltage (field excitation if used typically remains constant). A great many motor applications do not require ultra precise speed control.
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. • Inner Current Loop Regulator - Inherent high bandwidth capability for fast response. • Semiconductor Fusing - Both AC lines fused for maximum protection in case of short circuit.
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.
Enclosed Models F3N2C F3N2E Chassis Models F3N5E F3N5C Specifications Ratings Output AC Input Catalog Enclosure 1Ø Armature Field Field Armature Part # Volts Amps Volts Amps Volts Amps F3N2C Chassis ¼ -1 ½-2 F3N2E NEMA 4/12 ¼ -1 ½-2 F3N5C Chassis F3N5E NEMA 4/12...
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 C ONDITIONS...
PERATOR FUNCTIONS Chassis Enclosed Speed Adjustment (Speed Pot) Standard Standard Start/Stop Customer Supplied Standard Auto/Manual Optional Optional Run/Jog Optional Optional CONTROL CIRCUIT SPECIFICATIONS Logic Control Power 24 Vdc Speed Potentiometer 5000 ohms Input Signal Requirement 10 Vdc @ 0.5mA Control Circuit Isolation Optional with non-regen F3N models Standard with regen F3R models Current Signal Follower...
Focus 3 Chass is Dimensions Chassis Suitable for mounting in a user’s enclosu e where internal temper atures will not exceed SMALL REGEN & NON-REGEN MOUNTING 3.30" 9.75" 9.35" JP11 0.25" F3N2C 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 ppropriate enclosure has been supplied.
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).
ocus 3 O ption Kits Focus 3 Dynamic Braking Kit PN– See Table Below For use with Focus 3 Contactor Kits. Dynam braking provides rapid motor stopping by quick dissipating the stored energy in the rotating motor and load. These resistors have been sized in accordance with Nema specifications for dynamic braking.
Focus 3 Option Kits AC Tachometer Input Board – P/N F3ACT his option kit allows the Focus 3 to accept AC achometer feedback. It mounts directly to the focus c board and accommodates a range from 45 to 10vac at maximum speed. Signal Isolat r Bo ard –...
Focus Family Options peed Remote Opera or Station – P/N 2950-9068 /2950-9066 Speed These NE MA 1 operator stations can be used to remotely control Fo cus 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...
Speed Potentiometer – P/N SpdPot This potentiometer can be used for either a remote speed command potentiometer remote current limit potentiometer. 120Vac Inte rface – P/N ACIF-2R-Focus – Run/Stop & Jog This kit is ava ilable for the Focus series of drives. It is des igned 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 pro edures can re sult in personal injury or equipment damage. Only qualifi lect rical main tenan...
ncoming Power Requirements A remote fused AC line disco nnects or circuit breaker installed ahead of the control is required by the NEC (Natio al Electric l 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 eatsink, for safety of operating personnel.
Motor Thermal Switch F or 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.
Drive Power Wiring ¼ - 2 HP Focus 3 Models F3N2E & F3N2C Earth Connection AC Line Input 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 24...
Drive Power Wiring 3 - 5 HP Focus 3 Models F3N5E & F3N5C AC Line Input A+ & A- are the motor Earth Armature leads Connection F+ & F- are a shunt wound motors Field leads ( they will not be present on Permanent Magnet or Universal Motors ) Page 25...
Control Wiring TERMIN AL CONNECTIONS (TB2) & DESCRI PTIONS in 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.
ERMINAL CONNECTIONS (TB2) & DESCRIPTIONS Drive Signal Common Connection: Drive circuit common connection. Never con nect this terminal to Earth Ground. Since this terminal is connected internally to the drive power terminal A+ , earth grounding this connection is e quivalent to earth grounding the incoming power supply through the con...
The F3N drive control circuitry is not isolated *. No points in the control circuitry, including common, should be connected to earth ground unless specifically s hown on the supplied wiring diagrams. No grounding connections should be made on the terminal block. Improper connections to ground, including speed potentiometer connections, will result in immediate control failure and will void the factory warranty.
Terminal Strip Connec tions Enclosed Model Stan dard Start / Stop & Speed Potentiometer Connections Drive will not sta without this The Start/Stop Swi And the Speed Potentiometer are supplied as shown on the drive cove Chassis Model The Chassis Model has no operator devices connected to the drive control terminal strip.
Optional Terminal Strip Connections Note : It is strongly recommended that all remote control connections to the drive (i.e. speed pot, tart / stop etc.) are wired with shielded cable for noise immumity. These are all low voltage ignals. No connections are to be tied to earth ground. Two Wire ON / OFF with remote 0 to +10Vdc Speed command...
Typical 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 sh ielded cable for noise imm umity. These are all low voltage signals. No connections are to be tie d to earth ground.
ypical Terminal Strip Connections Note: It is stron gly recommended that all remote control connections to the drive ( i.e. speed pot, start / stop etc.) are wired with shielded cable for noise immumity. These are all low voltage signals. No connections are to be tied to earth ground. Drive will not Start without this ! Three Wire Start / Stop With Run / Jog Selector Switch...
Standard Unipolar Speed Potentiometer Wiring +10vdc Wiper Ref. Common Speed Pot Rear View 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...
Customer Jumper Selections Jumper Programming Equipment damage and/or pe rsonal injury may result if jumper p rogramming is attempted while control is operational. Always lock out power at the remote disconnect before changing jumper position . s See page 36 for jumper locations JUMPER DESCRIPTION RANGE FACTORY SETTING...
urrent Feedback Range (JP9) FOCUS Catalog DC Output Current Number (Amps) Jumper Position No Jumper (1/4 – 2 HP) F3N2C F3N2E No Jumper (3 – 5 HP) 13.8 F3N5C F3N5E 18.75 Current Control Mode ocus 3 Drives can be configured to operate in the Curren t Control Mode which is often ferred to as making the drive a “Current Regulator”.
Programming Jumper Locations Current Limit Pot selection Loca l or Remote / JP7 Optional Motor Contactor control Regul tion connection Mode Speed / Current Maximum 50 / 60 Hz Output Opera tion Current (in = 6 0Hz) Selection Arma ture / Tachometer Tacho meter...
Jumper Programming Photo shown jumpered for 120Vac input JP3-Tach Feedback Range JP11 ---- Input Voltage - 6.5 to 17.4 Vdc 120 Vac A to E - 60 to 160 Vdc & B to D JP4 -------- Feedback Selector 240 Vac A to C Tachometer (Tach) &...
JP6 & JP7 --- Remote JP9 -- Max Output Current Current Limit (100%) Pot Select Removed - 2.7 A Local – Uses Current A – 5.5 A Limit pot on B – 6.4 A Control Board C – 7.5 A D –...
LED Status Indicator – 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...
ternal Adjustments I Potentiometers Jumpers and pots shown in Factory positions Factory Calibration Do Not Adjust ! Current Limit Current Stability (ISTB) Acceleration Time Velocity Stability (VSTB) Jog Speed Speed Loop Offset Deceleration Time Maximum Minimum Speed Speed Follower Zero Bias Adjust Compensation Voltage...
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 enclosu re cover/operator control panel fully clockw ise while...
Basic Customer Adjustmen Acceleration Local Current Limit Limits maximum Output Curre Deceleration Time adjustments JOG SPEED Sets Jog Spee MAX SPD MIN SPD Adjust for maximum Motor speed Adjust for minimum Motor speed Page 42...
Additional Tuning Adjustments Internal Resistance Compensation ( IR COMP ) Compensation pot is used to overcome the motor’s natural tendency to slow dow as the load increases. If the motor slows down excessively as it is loaded, adjus IR COMP pot clockwise to recover speed lost during the loaded condition. Th tor will oscillate in speed or “hunt”...
Additional Tuning Adjustments Current Stability Velocity Stability (ISTB) (VSTB) Adjust for curre Adjust for speed loop loop stability stability Speed Loo p Offset Factory IR Comp Adjustment Adjust for zero creep Adjust for motor spee only speed droop due to load DO NOT ADJUST *** See page 74 for re-adjustment procedure.
Optional Tuning Adjustments The fo llowing adjustments are only required when either the current follower input (i.e. 4-20 mA input) or the voltage follower input (i.e. tachometer follower) is used. Only one of these inputs may be used. Terminal #16 must be tied to +24 Vdc (terminal #1) to activate the follower input speed command;...
Optional Tuning Adjus tments Current Ref Gain Speed Ref Gain Zero Bias Page 46...
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 F3N2C or...
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...
Armature Current Programming - (JP9) Current Feedbac k Range STEP 7 Are you applying a Focus Model F3N2C or F3N2E ? 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...
Initial Start-Up The following procedure is to verif y proper operation of the drive in its simplest form as 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 pr ogramming with t he exception of what was just...
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.
nitial Start-Up con’t . 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 ! . Start drive. Run light (red) and Current limit light (yellow) are illuminated. 3.
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 termin al strip connections as required by the particular application. Refer to pages 30-32 for typical Terminal Strip Connections.
ocus 3 Trouble Shooting Guide PORTANT SAFEGUARDS ll work on the drive should be performed by personnel familiar with it and its pplication. Before performing any maintenance or troubleshooting, read the structions and consult the system diagrams. Only minor adjustments should be ecessary on initial start-up, depending on the application.
TROUBLESHOOTING O VERVIEW ast and effective troubleshooting requires well-trained personnel supplied with the ecessary test instruments as well as a sufficient stock of recommended spare parts. Capable electronic technicians who have received training in the contro l operation and who are familiar with the application are well qualified to service this equipment. ggested Training A.
ASIC 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 cribed. BEFORE PROCEEDING WITH ANY MAINTENANCE OR TROUBLE-SHO OTING CTIVITY , 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.
OTOR RUNS IN WRONG DIRECTION A. The Al and A2 output leads to the motor are incorre ctly wired - exchange these leads. B. On shunt wound motors only the shunt field Fl and F2 leads are incorrectly wired – exchange these leads.
asic 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.
Record Drive Set-up EFORE 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 b ulb to ary in brightness from nothing to full brightness.
Retrofitting Focus 2 Drives with Focus 3 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 ompatibility and available options. Physical size and mounting: The enclosed Focus 3 drives are all slightly smaller in physical size than the Focus 2 drives, the mounting hole locations though are different.
Electrical Compatibility: he 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...
Available options: Focus 3 Focus 2 Jog at J og Speed Standard Optional Curr ent/Voltage follower ndard ptional Remote Current Limit Standard Optional ma 4/12** Standard Optional AC Tach Feedback Optional Standard ference Isolator Available ilable Reversing Focus 3 Regen Driv Option ** E nclosed Units...
Application Notes In order to provide continuing support for the Focus products (as well as all of our other ts): ( if this is being viewed elec tronically, click on any blue item for link ) Application Notes (CTANXXX) Technical Notes (CTTNXXX) Replacement Instructions (CTRIXXX)
TAN #130 Focus 3 Drives in Tachometer Follower Application 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 second drive as a speed command.
Focus 3 Non-Regen Master / Follower Application Moto Motor Arma ture Armature Motor Thermal Motor Thermal FOCUS 3 FO US 3 Stop Stop Start Start Drive run enable Drive run enable Motor Field Motor F ield Regen egen Manual only Manual Auto Auto...
CTAN #215 Ways of Achieving Isolation Non-Regenerative DC Drives F3N2C / F3N2E / F3N5C / F3N5E Focus F3N non-regenerative motor controllers are not isolated from the power circuit. Essentially, circuit common on the control card is connected directly to the A+ terminal f the motor.
Damage to Focus 3 Circuit Board caused by connecting speed potentiometer to earth ground. Typical Damaged circuit trace due To earth ground connection on Control terminal strip Page 70...
Solutions to Applications Requiring Control Inputs to be Earth Grounded lution #1 – Focus 3 Signal Isolator Boar Stop Speed F3NSBD Or signal from a PLC or computer DCS system where isolation is unknown or must be maintained Focus Terminal Strip 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...
Solution #2 – Isolation Transformer Isolation Transformer 120 / 240 Focus 3 Non-regen 120 / 240 VAC Input DC Drive VAC Output Heat Sink GND Lug DO NOT CONNECT GROUND TO TRANSFORMER SECONDARY Transformer KVA = 1.5 x Rated Armature Current x 120 Vac (or 240) Example : Your DC Motor has a 10 A armature KVA = 1.5 x 10 A x 120 Vac = 2.4 KVA (use 2.5 KVA)
Critical Components and Replacement Parts Main Control Board This control board is us ed on both the all Focus 3 non-regen models: F3N2C F3N2E F3N5C F3N5E The low horsepower units, F3N2C and F3N2E use the board as it is shipped. Replacement Instruction for Control Board (CTRI1210) can be found at our website at:...
Calibration procedure for adjustment of current feedback offset adjustment potentiometer 0.010 Term#12 With power applied to the drive but NOT in run. Measure the dc voltage at JP9 (any of the free pins on the left side) with respect to signal common (terminal #12).
INDEX Adjustments · 2, 3, 21, 40, 42, 43, 44, 45, 46 per Settings Accel/Decel · 58 rrent Limit · 9, 12, 27, 39, 54, 64 Current Limit · 9, 12, 27, 39, 54, 64 Current R anges · 3 IR Comp ·...