Control Techniques Focus 3R User Manual

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Focus 3R

¼ to 5HP Single Phase

Bi-Directional

Regenerative DC Drive

Page i

General Information

The manufacturer accepts no liability for, 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.

Page ii

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. That is why we offer you so many ways to get the support you need. 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:

Fax (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

Website: www.emersonct.com

Email: info@emersonct.com

If you have Internet capabilities, you also have access to technical support using our website. The website includes technical notes, frequently asked questions, release notes and other technical documentation. This direct technical support connection lets you request assistance and exchange software files electronically.

Technical Support (716) 774-1193 or (800) 893-2321

Email: pdtechsupport@emersonct.com

Control Techniques’ products are backed by a team of professionals who will service your installation. Our technical support center in Grand Island New York is ready to help you solve those occasional problems over the telephone. Our technical support center is available 24 hours a day for emergency service to help speed any problem solving. Also, all hardware replacement parts, if needed, are available through our customer service organization. When you call, please be prepared to provide the following information:

The type of controller or product you are using What you were doing when the problem occurred

How you tried to solve the problem Need on-site help? Control Techniques provides service, in most cases, the next day. Just call Control Techniques’ technical support center when on-site service or maintenance is required.

Customer Service (716) 774-1193 or (800) 367-8067

Email: customer.service@emersonct.com

Authorized Control Techniques distributors may place orders directly with our Customer Service department. Contact the Customer Service department at this number for the distributor nearest you.

Page iii

“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 iv

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.

You should give close attention to the electrical installation and system design to avoid hazards either in normal operation or in the event of equipment malfunction. System design, installation, commissioning and maintenance must be carried out by personnel who have the necessary training and experience. Read and follow this safety information and instruction manual carefully.

Enclosure

This product is intended to be mounted in an enclosure that prevents access except by trained and authorized personnel and prevents the ingress of contamination. This product is designed for use in an environment classified as pollution degree 2 in accordance with IEC664-1. This means that only dry, nonconducting contamination is acceptable.

Setup, Commissioning and Maintenance

It is essential that you give careful consideration to changes to drive settings. Depending on the application, a change could have an impact on safety. You must take appropriate precautions against inadvertent changes or tampering. Restoring default parameters in certain applications may cause unpredictable or hazardous operation.

Safety of Machinery

Within the European Union all machinery in which this product is used must comply with Directive 89/392/EEC, Safety of Machinery.

The product has been designed and tested to a high standard, and failures are very unlikely. However the level of integrity offered by the product’s control function – for example stop/ start, forward/reverse and maximum speed – is not sufficient for use in safety-critical applications without additional independent channels of protection. All applications where malfunction could cause injury or loss of life must be subject to a risk assessment, and further protection must be provided where needed.

Page v

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. The installation must comply with all relevant safety legislation in the country of use.

AC supply isolation device

The AC supply must be removed from the drive using an approved isolation device or disconnect before any servicing work is performed, other than adjustments to the settings or parameters specified in the manual. The drive contains capacitors, which remain charged to a potentially lethal voltage after the supply has been removed.

Grounding (Earthing, equipotential bonding)

The drive must be grounded by a conductor sufficient to carry all possible fault current in the event of a fault. The ground connections shown in the manual must be followed.

Fuses

Fuses or over-current protection must be provided at the input in accordance with the instructions in the manual.

Isolation of control circuits

The installer must ensure that the external control circuits are isolated from human contact by at least one layer of insulation rated for use at the applied AC supply voltage.

Page vi

Table of Contents

Topic Page

Introduction 4 Motor Compatibility 5

Basic Control Modes/Feedback 6

Armature Voltage Feedback 6 Speed or Tach Feedback 6

Quick Stops 6 Receiving, Inspection, Storing 7 Performance Features 8 Nameplate Information 9 Nameplate Location 9 Catalog Number Definition 9

Specifications Ratings Table 10

Performance Specifications 11 Operating Conditions 11

Internal Adjustments (Potentiometer) 11 Customer Selections (Jumpers) 11 Operator Functions 12 Control Circuit Specifications 12 Options 12 Dimensions 13-14 Option Kits & Descriptions 15-19

Customer Connections & Start-Up

Start-Up Guidelines 20 Incoming Power Requirements 21 Grounding 21 Motor Wiring 21-22

When viewing this document electronically, the Table of Content items

are active and will direct you to that topic by clicking on that item.

Page 2

Table of Contents

Topic Page

Power Wiring 23-24

Control Wiring 25-32

Speed Pot Wiring 33

Customer Selections

Jumper Programming 34-38

Current Ranges 35

Current/Torque Control 35 LED Status Indicators 39 Potentiometer Adjustments 40-46

Basic Adjustments 41-42

Tuning Adjustments 43-44

Interconnect Drawings

Functional Block Diagram 48 Non-Regen Circuit Overview 49

Start-up Guide Worksheet 50-52

Initial Start-Up & Basic Test Setups 53

Installation of Option Kits 53

Motor Test 54-56

Trouble Shooting Guide 56-59

Light Bulb Test 61-62

Retrofitting Focus 3 to Focus 2 Applications 63-65

Application Notes 66

Tachometer Follower Application 67-68

Spare Parts 70

When viewing this document electronically, the Table of Content items

are active and will direct you to that topic by clicking on that item.

Page 3

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. The Focus 3 Regen is a single-phase, bi-directional analog drive for DC motors with power ranges from ¼ to 5HP.

Your Focus 3R is a general purpose regenerative DC motor speed controller that is powered from either 115Vac or 230Vac single phase power. A regenerative (four quadrant) drive is one that can provide motoring and regenerating torque for acceleration and deceleration to overcome rated loads. There are a great many applications where regenerative drives provide the most economical solution. A regenerative drive can slow down a motor faster than the motors normal coasting rate and can stop overhauling load situations.

Both drives incorporate many features that are standard on high performance system drives, such as dynamic stability and built-in signal follower adjustments. Focus 3 drives come 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.

(5 Hp model shown)

Enclosed Model

The Enclosed version comes to you already in a NEMA 4/12 enclosure that would allow the User to mount the Focus on a wall or machine surface. The Enclosed version has Start/Stop and the Speed Control adjustment on the front cover for convenient operation.

For a complete overview of the Focus 3 product line and available options, visit our website at:

www.emersonct.com or click the link below:

Focus 3 Catalog Section

Page 4

Motor Compatibility

The Focus 3 was designed to run standard 90 Vdc or 180 Vdc Shunt Wound or Permanent Magnet DC motors in both directions. 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. Universal motors are often used in tools such as Drills, Saws, Shop VAC’s, Routers, etc and typically cannot be run in reverse.

Shunt Wound Motors that are controlled by single phase DC drives typically have 4 power wires. Two of these are the Armature leads typically designated A1 & A2 or A+ & A-. The other two power wires are the shunt field leads and typically designated F1 & F2 or F+ & F-. The Focus 3 can supply up to 1 Amp for shunt field excitation (field current requirements beyond 1A may damage field rectifier diodes). If your motor does not have Field Current information on the nameplate, you can determine compatibility by measuring your motors Field resistance using a calibrated ohmmeter.

Motors with:

90v Armatures typically require 100 Vdc for field excitation. In these cases, the Focus

3 requires 120vac input power and must be internally set for this input level. The motor Field resistance should not be less than 100 ohms when cold.

180v Armatures typically require 200 Vdc for field excitation. In these cases, the Focus 3 requires 240vac input power and must be internally set for this input level. The motor Field resistance should not be less than 200ohms when cold.

The motor nameplate information is key to determining compatibility. As seen below, the motor below easily falls in the range of the Focus 1 operated from a 240vac supply. The drive will supply 180v for the armature and 200v for the field ( this motor indicates there are 2 field windings and for 200vdc they must be wired in series ). The field current requirement is 0.28A which is well under the 1A maximum.

1 1750 / 2050 180

5.0 SHUNT

0.28/.22 518

FLD VOLTS 200/100

240v Armatures typically require 150 Vdc for field excitation. In these cases, the Focus

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 5

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 Voltage

Armature Current

Page 6

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. Because of this, the Focus 3 is factory set for Armature Voltage Feedback. Armature Voltage Feedback (or simply Armature Feedback) does not require any special motor mounted speed feedback device and is therefore inherently quite reliable and is capable of providing up to 1% speed regulation.

Speed Feedback- Tachometer

Should more precise speed control be required, the Focus 3 can accommodate those motors equipped with DC Tachometers (AC tachometers require an option kit). DC tachometers output a linear voltage proportional to their RPM and can provide the Focus 3 with accurate motor speed feedback information. With good DC tachometers up to

0.5% speed accuracy can be achieved.

Tach failure will typically result in motor speed runaway. One who designs

systems with Speed Feedback devices such as DC tachometers should be

cognizant of this fault condition and must take machine design precautions

should this event occur.

We would recommend that all DC Drives be initially run using Armature Voltage Feedback to verify operation even if Tach Feedback is the ultimate goal.

Quick Stops

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.

Regenerative drives are capable of stopping the motor more quickly than dynamic braking by rapidly reducing the speed command to zero and then disabling the drive. This requires the drive to be active and some external means of disabling the drive after the motor reaches zero speed.

Power Outages

Shunt Wound Motors

Should a power outage occur, the drive would turn off and the motor would coast to rest. If a Dynamic Braking resistor were employed there would typically be enough decaying field strength to enable some faster stopping action.

Permanent Magnet Motors

Should a power outage occur, the drive would turn off and the motor would coast to rest. If a Dynamic Braking resistor were employed, full Dynamic Braking force would be exerted because the field is maintained by the motors internal permanent magnets. Therefore, there would be motor turning resistance during power outages as well.

Note: DB Resistors require Contactor Option - See Options

Page 7

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.

Receiving

The user is responsible for inspecting the equipment thoroughly before accepting the shipment from the freight company. Check the items received against the purchase order. If any items are obviously damaged, do not accept delivery until the damage has been noted on the freight paperwork.

Inspection

Before installation and start-up of the drive, inspect the unit for mechanical integrity (i.e. loose parts, wires, etc). If physical damage was sustained during shipment, leave the shipping container intact and notify the freight agent. After unpacking, check the drive nameplate catalog number against the purchase order.

Storing

Store the drive in its shipping container prior to installation. If the drive isn’t used for a period of time, store according to the following instructions in order to maintain warranty coverage:

Clean, dry location

Ambient Temperature Range: -400C to 700C

: -400F to 1600F

Humidity: 95%, Non-condensing

Improper procedures can result in personal injury or equipment damage. Only qualified electrical maintenance technicians familiar with electronic drives and thei standard safety precautions should be permitted to install, start-up, or maintain this apparatus.

Page 8

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.

• Control Circuit Isolation – The control circuitry is isolated from the drives power section

allowing signal common to be connected to earth ground or process signals referenced to earth ground.

• 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.

• AC Line Filter and Transient Voltage Suppressor Network - Eliminates interaction

between other drives or AC equipment.

• Current Limit Ranges - Selectable current limit ranges to match the drive to the motor

being used. Provides smooth acceleration of high inertia loads.

• Speed Regulator - 1 % accuracy armature voltage feedback with IR compensation or 0.5 %

accuracy with DC tachometer feedback. Regulation accuracy may be affected by the tachometer selected.

• Current (Torque) Regulator -

2% accuracy armature current regulator allows the user to control motor torque instead of speed.

• Circuit Board Indicators - Light emitting diodes (LEDs) on the control board indicate when

the drive is in Run Mode or the Current Limit is enabled.

• Remote Current Limit - Available by the simple addition of a potentiometer.

• Current Signal Follower lnput** - Allows the motor speed to be controlled by a current

signal from a commercially available transducer. The signal may be one of the following:

0 -5mA or 0-20mA

• Voltage Signal Follower lnput - Allows the motor speed to be controlled by a voltage

signal from a DC tachometer generator or a process voltage signal. It accepts an input with a range of 0-200 Vdc.

• Auto/Manual Operation - Standard circuitry allows the drive to be controlled by the

operator speed potentiometer or by the current/voltage signal inputs.

• UL/cUL - All Focus 3 Drives are UL/cUL listed.

** Note: The Current Signal Follower Input on the Focus 3 Regenerative Drives is designed for 0

to 5 or 0 to 20 ma, not 1 to 5 or 4 to 20 ma. The circuitry can be adjusted to bias out the 1 or 4 milliamp current levels and the drive will follow the signals correctly. The difference is that if the current input drops below the 1 or 5 ma level, the drive will rotate in the reverse direction ( as much as 25% speed if the signal goes to zero). If a 1 to 5 or 4 to 20 ma signal is required on a Focus 3 Regenerative Drives, it is recommended that the Focus 3 Signal Isolator board (F3NSBD) be used since it has circuitry built in to block the reverse speed signal.

Page 9

The Focus 3 comes in two basic model variations- with and without enclosure.

Chassis Model

Enclosed Model

Nameplate Information

Enclosed Unit

Model #

Model Number Definition

F3 N 2 C

Part #

Serial #

Enclosure

Chassis (C) Enclosed (E)

Max HP Rating @240vac

2 HP (2) 5 HP (5)

Always record the drive Model Number, Part Number and Serial Number for future warranty situations and spare parts. A good location to record these is on the Start-up

Guide Worksheet on page #49.

Page 10

Non-Regen (N) Regen (R)

Drive Family

Focus 3 (F3)

Chassis Models

Enclosed Models

F3R2C

F3R2E

F3R5E

F3R5C

Specifications

Ratings

Input

Catalog Enclosure HP 1Ø Max

Part #

F3R2C Chassis ¼ -1

½-2

F3R2E NEMA 4/12 ¼ -1

½-2 F3R5C Chassis 3-5 240 35 180 25 200 1 F3R5E NEMA 4/12 3-5 240 35 180 25 200 1

Volts Amps Volts Amps Volts Amps

120 240 120 240

14 14 14 14

Armature

DC Output

180

Armature Field Field

10 10 10 10

100 200 100 200

1 1 1 1

Page 11

Page 12

PERFORMANCE SPECIFICATIONS

Service Factor 1.0 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 98% Drive System (motor and control) 86% typically

DRIVE OPERATING CONDITIONS

Altitude (without derating) 3300Ft ( 1000meters ) Ambient Temperature:

Chassis Models 0-550C ( 32-130° F ) Enclosed (NEMA 4/12) 0-400C ( 32-104° F )

INTERNAL ADJUSTMENTS (POTENTIOMETERS)

Potentiometer Function Range

Maximum Speed 80-120% of Rated Speed Minimum Speed 0-30% of Maximum Speed IR Compensation 0-20% of Rated Voltage Current Limit 0-150% of Selected Range Acceleration Time 0.3-20 seconds (linear) Deceleration Time 0.3-20 seconds (linear) Jog Speed 0-30% of Full Speed command Speed Loop Offset Adjustable Velocity Loop Stability Adjustable Current Loop Stability Adjustable Current Signal Follower Gain Adjustable Velocity Signal Follower Gain Adjustable Signal Follower Zero Bias Adjustable

CUSTOMER SELECTIONS (JUMPERS)

Function Range

Input Voltage 120/240Vac Control Mode Speed / Torque Current Feedback range High / Medium / Low / Xlow Current Limit Pot Selector Local / Remote Armature Voltage level 90 Vdc/180 Vdc Optional “M” Contactor Yes/No Tachometer Feedback High/Low Speed Feedback Selector Armature / Tachometer Line Frequency 50/ 60Hz

Page 13

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 (see note, page 8) 0-5mA or 0 - 20mA

Voltage Signal Follower 10 – 200 Vdc (at Maximum Speed)

FOCUS 3 OPTIONS

CATALOG NUMBER DESCRIPTION

F3SE Enclosure Small (2HP), NEMA 4/12 F3LE Kits Large (5HP), NEMA 4/12

F3M112 “M” ¼ - 1HP @ 120V F3M224 Contactor ½ - 2HP @ 240V F3M524 Kits 3 - 5HP @ 240V F3DB224 ½ HP @ 120V, 2HP @ 240V F3DB1524 ¼ - 1/3 HP @ 120V, I .5HP @ 240V

F3DB124 Dynamic ¾ -1HP @ 240V F3DB0524 Braking ½ HP @ 240V F3DB112 Kits ¾ -1HP @ 120V F3DB324 3HP @ 240V F3DB524 5HP @ 240V

F3TS Toggle Switch, NEMA 4 /12 F3NSBD Signal Isolation Board 2450-9024 Remote Percent Speed Meter Kit 2450-9021 Remote RPM Speed Meter Kit 2950-9066 Remote Operator Station ( 3 Function ) 2950-9068 Remote Operator Station ( 5 Function ) 6160-9001 Ten-Turn Precision Potentiometer

Page 14

Focus 3 Chassis Dimensions

Chassis

Suitable for mounting in a user’s enclosure where internal temperatures will not exceed 550C or 1300F.

TB2

SMALL REGEN

NON-REGEN

MOUNTING

9.75" 9.35"

JP11

3.30"

AC1 AC2

0.25"

13.00"

12.00"

B B

LAL

0.168" (4 PLACES)

F3R2C

6.36"

6.75"

TB2

LARGE REGEN &

NON-REGEN

MOUNTING

TB1

C C

JP11

4.50"

AC2 G2

0.13"

8.88"

9.50"

0.312" (4 PLACES)

F3R5C

Page 15

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. Ambient temperature is not to exceed 400C.

5.93

9.35

4.63

12.00

6.36

8.88

0.168 Dia (4 Places)

6.91

0.51

6.13

F3R2E

3.70

9.50

2.102.22

1.05

0.13

1.05

Page 16

Ø0.31

F3R5E

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 (fou enclosed drives and four chassis drives). It includes the speed adjustment potentiometer and the start/stop switch pre-wired to a plug-on terminal strip and all seals to provide a NEMA 4/12-enclosure rating.

Focus 3 Contactor Kit – P/N F3M112 (1 HP,120vac)

P/N F3M224 (2 HP, 240vac)

This Kit includes a magnetic contactor that can be mounted either in the Focus 3 enclosed unit or on the chassis mount unit. It provides a positive disconnect o the motor armature when the controller is stopped, preventing motor rotation in the event of SCR mis-fire due to line noise. This kit may also be required by local and/or National Electrical Codes. This kit also includes the DB (dynamic braking) poles, an auxiliary normally open contact and all connection wires.

Focus 3 Contactor Kit– P/N F3M524 (3-5 HP, 240vac)

Page 17

Focus 3 Option Kits

AC Input HP (Typical) Part Number

120 Vac

240 Vac

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 moto and load. These resistors have been sized in accordance with Nema specifications for dynamic braking.

“Providing 3 stops in rapid succession with the load inertia equal to the motor inertia, then cooling forever.”

Note: Large and small dynamic braking resistors shown, ¼-2 HP use small and the 3-5 HP use the large resistor.

1/4-1/3

1/2

3/4-1

1/2

3/4-1

1.5 2 3 5

F3DB1524

F3DB224 F3DB112

F3DB0524

F3DB224

F3DB1524

F3DB224 F3DB324 F3DB524

Page 18

Focus 3 Toggle Switch – P/N F3TS

This kit can be mounted in the drive enclosure cove or remote mounted when used with chassis drives. The kit includes the switch, NEMA 4/12 switch boot and the connection wires for enclosure use. It is used to provide one of the following functions: Fwd/Rev, Run/Jog, or Auto/Manual. Up to 3 o these kits may be used with the Drive cover.

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). It may also be used simply to isolate the speed adjustment pot, and the pot power supply is included. This option can be mounted in the enclosure or in a piece of plastic track (included with kit).

Specifications:

Input Power: 17- 30 Vdc @ 50mA Max. (for control circuitry)

Control Relay (CRR): 24 Vdc @ 12.1 mA (JP5 = 24 Vdc)

120 Vac @ 20 mA (JP5 = 120 Vac) Contact Type/Rating – 2 Form A / 1A @ 250 Vac

Isolation Voltage: 240 Vac Power Systems

2000 Vac Hi-Pot for 1 Minute

Inputs:

Voltage Ranges: 5,12,26,52,98 & 208 Vdc, 180 Ohms/volt

Current Ranges: 0-5 mA, 1-5 mA, 910 Ohms input impedance

0-20 mA, 4-20 mA, 250 Ohms input impedance

Speed Pot: 5Kohms, 2W (Includes +10 Vdc power supply for potentiometer)

Output: 0 to +10 Vdc (Uni-polar)

Application Note:

Although the Focus 3 Regenerative drives are isolated, this board is useful in applications requiring control with a 4-20 milliamp speed reference since the drive was designed for a 0-20 milliamp signal. It also adds an additional layer or isolation. In addition, the adjustments on this board are multi-turn adjustment potentiometers providing much finer adjustments than the ones on the drive.

Page 19

Focus Family Options

Speed

Remote Operator Station – P/N 2950-9068 /2950-9066

Speed

Run Jog

Auto Man

Start

Stop

100 100

Start

Stop

100

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 Potentiometer, a green normally open start button and a red normally closed stop button. The 2450-9068 also includes two two- position switches with two contacts, 1 normally open, 1 normally closed.

Remote Percent Meters – P/N See Accessories Catalog

This meter may be used to remotely display the motor speed in percent of maximum speed. Included is a calibration board. It is available in left zero (unidirectional applications) or 0-center (bidirectional applications) Meters supplied loose for customer mounting.

P/N Meter P/N Calibration board

M1 Meter 0 - 100 C1 Cal+/-10vdc M2 Meter 0 - 150 C2 Cal-90vdc M3 Meter 100 –0 -100 C3 Cal-180vdc M4 Meter 150 –0 -150

Ten-Turn Precision Speed Potentiometer – P/N 6160-9001

This is a multi-turn speed potentiometer. It provides a vernie scale for precise and repeatable speed setting. A locking tab is provided to prevent in advertent speed changes. It may be mounted in either of the Focus 1 and Focus 3 enclosures or the Remote Operator Station described above.

Page 20

These options are used with the chassis mount controls and include Din rail for panel mounting in the customer’s enclosure.

Speed Potentiometer – P/N SpdPot

This potentiometer can be used for either a remote speed command potentiometer or a 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. Operato Stations shown on previous page).

120Vac Interface – P/N ACIF-6R-Focus – Run/Stop

Forward/Reverse, Jog and Auto/Manual

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. Operato Stations shown on previous page).

Page 21

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.

Start-up Guidelines

STEP 1: Receiving & Inspection Page 7 STEP 2: Drive Installation . . . Page 21 STEP 3: Power Wiring Pages 22-24 STEP 4: Control Wiring Pages 25-32 STEP 5: Jumper Programming Pages 33-37 STEP 6: Potentiometer Adjustments Pages 39-45 STEP 7: Start-up of Drive Page 48-54

Installation of this equipment must be done in accordance with the National Electrical Code and all other applicable regional or local codes. Proper grounding, conducto sizing, and short circuit protection must be installed for safe operation. Imprope installation or operation of this control may cause injury to personnel or damage to equipment.

Hazardous voltages may be present on external surfaces of ungrounded controls. This can result in personal injury or equipment damage.

When performing visual inspections and maintenance, the incoming AC power must be turned off and locked out. Hazardous voltages will be present until the AC power is turned off. The drive contactor does not remove hazardous voltages when opened.

Page 22

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. The ground wire should be of the same gauge as the AC Input wires and must be connected to the panel or enclosure frame for personal safety.

Wiring Guidelines for Focus DC Drives

Check drive nameplate data for conformance with AC power source and motor

Catalog HP Fusing Max

Part # Volts Amps AWG Volts Amps AWG Volts Amps AWG

F3R2C ¼ -1

½-2

F3R2E ¼ -1

½-220Amp

F3R5E F3R5E

3 60

5 60

Amp

250Vac

Amp

500Vac

Amp

500Vac

120 240

240 24 #10 180 15 #10 200 1 #14

240 40 #8 180 25 #8 200 1 #14

Input

16 16

Wire Armature

#14 90

180

#14 90

180

DC Output Shunt Field

Armature Wire Field Field Wire

10 10

#14 100

200

#14 100

200

1 1

#14

Notes:

All wiring based on 75° C copper wire, types FEPW, RH, RHW, THHW, THW, THWN, XHHW, USE, ZW

Wire gauge size based on 30° C maximum ambient and no more than three conductors in a raceway or cable and 1.25 service factor.

Please refer to National Electric Code Table 310-16 for additional information.

Wiring must also meet all Local Codes.

Do not place knife switches, polarity reversing switches, reversing contacts in the armature or field circuits.

During normal operation, keep all covers in place and cabinet doors shut.

Page 23

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.

Installation of Option Kits

Do not install option kits until you have verified the basic operation as outlined in the

Start-Up section.

Pre-installation of option kits before verification of basic drive operation will make troubleshooting much more difficult. Option kits are often installed incorrectly and one cannot determine if the drive was functional before kits were installed.

Page 24

Drive Power Wiring

)

¼ - 2 HP Focus 3 Models

F3R2E & F3R2C

F+ F- A+ A-

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

AC Line

Input

Earth

Connection

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

A+ A- F+ F-

Page 26

Control Wiring

TERMINAL CONNECTIONS (TB2) & DESCRIPTIONS

Pin Number

1 +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.

2 Tie Point: It has no internal connections and is used as a tie point for

the Motor Thermal or Stop button connection. see Application Safety

3 Run Input: When +24 Vdc is applied to this terminal, the Run relay picks

up, the Speed loop and the Current loop are enabled, and the clamp on the SCR firing circuits is released.

4 Run Relay Contact Output: Normally Open connection. Rated:

0.5amps @ 120VAC for non-inductive loads. It can be used as the seal-in contact in a three-wire run circuit or as the run contact feedback in a twowire system.

5 Run Relay Contact: Relay common connection.

6 Run Relay Contact: Normally Closed connection. Rated: 0.5amps. @

120VAC for non-inductive loads.

7 Jog Input: When +24 Vdc is applied to this input, the output of the

accel / decel circuit is electronically disconnected from the speed loop and the jog speed command (from the jog speed pot) is electronically switched in. This jog speed command can be configured as a Thread speed (maintained jog speed) by jumpering terminals TB2-3 & 4 in addition to the Run/Jog connections already shown on page 30.

8 Jog Potentiometer Supply voltage input: This terminal is typically

connected to the +10 Vdc (TB2-9) speed pot supply when jog is required.

9 +10 Vdc Speed pot / Jog supply voltage: Maximum load is 5ma

therefore the recommended Jog Pot value would be 5K ohms

10 Standard Speed command input: Typically this input is connected to

the wiper of the speed pot wiper. Input impedance: 20Kohm.

11 -10 Vdc Speed pot / Jog supply voltage: Maximum load is 5ma

therefore the recommended Jog Pot value would be 5K ohms

Page 27

TERMINAL CONNECTIONS (TB2) & DESCRIPTIONS

12 Drive Signal Common Connection: Drive circuit common connection.

13 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.

14 Remote Current Limit Potentiometer: Wiper connection. Jumpers JP6

& JP7 must be set to RMT position. Shielded cable should be used for wiring purposes if the pot is not mounted on the drive front cover. A standard pot (5Kohm) may be used – see Accessories/Options

15 Remote Current Limit Potentiometer: Clockwise connection. Jumpers

JP6 & JP7 must be set to RMT position. Shielded cable should be used for wiring purposes if the pot is not mounted on the drive front cover. A 5Kohm potentiometer should be used, see Accessories/Options Note: Counter clockwise connection and shield should be connected to terminal TB2 pin 12.

16 Auto/Manual Input: When +24 Vdc is applied to this terminal, the speed

command input to the accel/decel circuit is switched from the standard speed pot input to the follower (current or voltage) speed command derived from terminal TB2- pins 17 or 18. If the current/voltage follower is the only signal used, terminals TB2- pins 2 & 16 must be jumpered.

17 Current Signal Follower Input: positive input for external mA current

source. Input impedance: 100 ohms. Range: 0-5mA or 0-20 mA

** Note: The Current Signal Follower Input on the Focus 3 Regenerative Drives is designed for 0

For more detailed information click on the “blue” F3NSBD above.

18 Voltage Signal Follower Input: positive input for external voltage

source. Input impedance: 1 Kohm/volt. Range: 0-200 Vdc.

19 DC Tachometer Input: negative input from motor mounted DC

tachometer. Input impedance: 120 Kohm in the high position and 13.5K ohm in the low position. Range at maximum speed: 6.5 to 17.4 Vdc in the low position and 60 –160 Vdc in the high position. Note: virtually any tachometer voltage can be used with the addition of an external resistor in series with the tach lead (consult factory it required).

20 DC Tachometer Input: positive input from motor mounted DC

tachometer. Note: Cable shield should also be connected to this terminal.

Page 28

Terminal Block (TB2)

Installation

On chassis drives, the terminal block (TB2) is installed so that control wires are inserted into the terminal point from the right side of the block. For enclosed drives, the terminal block must be installed so wires extend up (900 angle) from the drive PC board. lf the control wires extend ou

to the side, there is not sufficien clearance space for the enclosure cover.

If the customer supplied moto

thermal is not used, pins 1 & 2 must be

umpered or the drive will not start.

NOTE:

Enclosed Units Wire Entry

Chassis Units Wire Entry

Shielded wire (2 or 3 conductor) is recommended for speed command and other signal wire connections. Shields should be taped off at the remote end. At the drive, connect shields to the circuit common, route wire away from high current lines (i.e. AC lines and armature wiring).

Recommended Cables and pots are available from :

Control Techniques Service Center

@ 1-800-367-8067

Signal & Control Wiring Entry

Page 29

Terminal Strip Connections

Enclosed Model

Standard Start / Stop & Speed Potentiometer Connections

Motor Thermal or Jumper

(customer supplied)

Sto

Chassis Model

Start

Drive will not start without this. This is intended for system interlock- see

pplication Safet

The Start/Stop Switch And the Speed Potentiometer are supplied as shown on the drive cove

The Chassis Model has no operator devices connected to the drive control terminal strip. The only connections made are connections from terminal #3 to #4 which is required for three wire Start/Stop controls.

The next four pages show various configurations of operator control devices and speed (or current) adjustment potentiometers. These can be used on Chassis models, which is typically the case, or the Enclosed models, which would require possible enclosure and internal wiring changes. The two wire configuration (top of next page) is commonly used for remote contol of the drive (i.e. PLC control).

Page 30

The Speed Potentiometer is supplied “loose” with the drive.

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

* Jumper installed at factor

Two Wire ON / OFF

with remote 0 to +10Vdc Speed command

Sto

Start

* Jumper installed at factor

Motor Thermal or Jumper (customer supplied)

Sto

Start

Run/Jog

Drive will not start without this. This is intended for system interlock- see

pplication Safet

Three Wire Start / Stop

With Uni-polar Speed Potentiometer

Drive will not start without this. This is intended for system interlock- see

pplication Safet

Three Wire Start / Stop with Run / Jog Selector Switch

* When using Jog function, remove factory installed

jumper from terms 3 & 4

and add to terms #8 & 9

Page 31

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 shielded cable for noise immumity.

Drive will not start without this. This

Motor Thermal or Jumper

(customer supplied)

Sto

Start

Run/Jog

(Switch shown in run position)

is intended for system interlock- see

pplication Safet

Three Wire Start / Stop with Run / Jog Selector Switch

With Uni-polar Speed Potentiometer

To Pin #1

With Manual / Auto Speed command Selector Switch (Manual – Speed Pot)

DC Tachometer Input

Current Signal Input

Voltage Signal Input

(Auto – Either Current Signal

Voltage Signal)

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

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 shielded cable for noise immumity. These are all low voltage signals.

Drive will not start without this. This is intended for system interlock- see

Motor Thermal or Jumper

(customer supplied)

Sto

Start

Run/Jog

(Switch shown in run position)

pplication Safet

Three Wire Start / Stop With Run / Jog Selector Switch

Speed Potentiometer

Current Limit Potentiometer

DC Tachometer Input

With Uni-polar Speed Potentiometer

With Remote Current Limit Potentiometer

With 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: Control Techniques Service Center @ 1-800-367-8067 Cable P/N 3CONCBL-XXX (XXX in feet)

Page 33

Typical Terminal Strip Connections

Drive will not start without this. This is intended for system interlock- see

Application Safety

Three Wire Start / Stop With Run / Jog Selector Switch

With Forward / Reverse Switch

Motor Thermal or Jumper (customer supplied)

Sto

Start

Run/Jog

(Switch shown in run position)

Forward / Reverse (shown in Forward)

DC Tachometer Input

Speed Potentiometer

With DC Tachometer Feedback

The Current Limit potentiometer is available from Control Techniques;

see accessories section, page 20

Page 34

Standard Unipolar Speed Potentiometer Wiring

+10vdc

Ref.

Min Spd

Common

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)

Wiper

CWCCW

Speed Pot Rear View

CCW=counter clockwise

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

JP1 Optional “M” Contactor Yes or No No Contactor

Sequencing Module (NO JUMPER)

JP2* Speed or Current Control Speed or Current Speed

Mode (see next page) (SPD) (CUR)

JP3 Tachometer Feedback Low (6.5-17.4 Vdc) or HI

Range (at max. speed) HI (60-160 Vdc)

JP4 Speed Feedback Selector Tachometer (TACH) or Armature

Armature (ARM)

JP6 Local or Remote Current Local or Remote (RMT) Local

Limit Pot Selector

JP7 Local or Remote Current Local or Remote (RMT) Local

Limit Pot

JP8 Armature Voltage LOW (90 Vdc) or HI (180 Vdc)

Level Selector HI (180 Vdc)

JP9 Current Feedback A thru D C

Range (see next page)

JP10 Line Frequency Selector 50 or 60Hz (w/ jumper) 60Hz

JP11 Input Voltage 120 or 240Vac 240Vac

Selector (see Table below)

Input Line Voltage JP11 Jumper Positions

120Vac A to E and B to D 240Vac

Items in BOLD RED are factory set positions

Page 36

A to C and B to C

Current Feedback Range (JP9)

FOCUS Catalog DC Output Current JP9

Number (Amps) Jumper Position

2.6 No Jumper

(1/4 – 2 HP) 5.5 A

F3R2C 7.5 B

F3R2E 10 C

5.2 No Jumper

(3 – 5 HP) 11 A

F3R5E 15 B F3N5E 20 C

25 D

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”. Since motor torque is directly proportional to the armature current, a drive configured as a Current Regulator is often referred to as a “Torque Regulator”.

*If using the Focus drive as Torque Regulator, make the following adjustments:

JP2: Select current (CUR) control JP4: Select tachometer (TACH) feedback, but do not use a tachometer. JP9: Select the appropriate current feedback range.

ACCEL and DECEL pots: Set to full counterclockwise position. LOCAL CURRENT LIMIT pot: Set to full clockwise position.

In torque control mode, the motor speed is determined by how much load there is on the motor and the torque level set on the drive. If torque in the motor (as set by the Drive) is set to a level higher than what is required to move the load, the motor will accelerate in speed until either the load from the motor increases to the level set by the drive or the drive reaches its maximum output voltage (as set by the line voltage). In the case of a lightly loaded motor,

the motor could accelerate to almost twice-base speed under these conditions.

In this mode the user be aware of this and MUST PROVIDE OVERSPEED PROTECTION.

Page 37

JP5

IR Comp

Positive Or Negative

JP2

Regulation Mode

Speed / Current

JP10

50 / 60 Hz Operation

(in = 60Hz)

Programming Jumper Locations

Optional Motor Contactor Control Connection

JP6 / JP7

Current Limit Pot Selection Local or Remote

JP4

Armature/ Tachometer

JP8

Armature Voltage Range

JP9

Maximum Output Current Selection

JP3

Tachometer Feedback Range Selector

JP11

AC Input Range Selection

Page 38

Jumper Programming

JP3-Tach Feedback Range

Lo - 6.5 to 17.4 Vdc Hi - 60 to 160 Vdc

JP4 -------- Feedback Selector

Tachometer (Tach) Armature (Arm)

JP8 --------- Armature Voltage

90 Vdc

180 Vdc

Bold Fonts indicate Factory Settings

JP11 ---- Input Voltage

120 Vac A to E

B to D

240 Vac A to C

Photo shown

umpered fo

240 Vac input

B to C

Page 39

JP9 -- Max Output Current

(100%)

Removed - 2.7 A and less

A – 5.5 A

B – 6.4 A C – 7.5 A

D – 10A

Select based on Armature

requirements

JP6 & JP7 --- Remote

Current Limit

Pot Select

Local – Uses Current

Limit pot on Control Board

Bold Fonts indicate Factor

Page 40

Settings

Remote – Uses remote

Current limit Potentiometer

LED Status Indicators

Run

Current

Run LED – This red led will illuminate any time the run relay is energised

Curr Lmt (Current Limit) LED – 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

2. The motor is at the maximum output voltage as possible based on the supply voltage.

3. The motor armature is open circuit ( no motor connected )

Page 41

Internal Adjustments I Potentiometers

Deceleration

Acceleration

Velocity Stability

Maximum

Speed

Jog Speed Adjust

Local Current Limit

Minimum

Speed

Current

Follower

Voltage

Follower

Speed

Rate

Page 42

Current

Stability

Follower Zero Bias Adjust

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+ & A-. Then, adjust the MAX SPD pot on the control board to set the desired maximum motor speed. Do not exceed the motors Armature Voltage nameplate rating.

Minimum Speed (MIN SPD)

The MIN SPD pot sets the minimum speed (0-30% of maximum speed setting) at which the motor will run. It is factory preset at its full counterclockwise position. With the motor running, turn the speed pot on the drive enclosure cover/operator control panel fully counterclockwise. Adjust the MIN SPD pot clockwise until the desired lowest motor speed is reached.

Acceleration and Deceleration Times (ACCEL / DECEL)

djust the ACCEL and DECEL pots clockwise to increase the linea acceleration and deceleration times (0.3-30 seconds). These adjustments are independent from each other. Note: Controlled deceleration time occurs when the speed pot is turned down, but not when the start/stop switch is placed in the STOP position. Note: When the drive is used in torque (current) control mode, the

CCEL/DECEL pots adjust how quickly the motor torque level changes as the

main torque pot is varied.

Local Current Limit (LOC ILMT)

Set the LOC ILMT pot to limit the motor armature current to 150% or less o the motor nameplate rating. It should represent the lowest level consistent with satisfactory operation. The pot is factory preset at 150% of the range selected by

umper JP9 (A-D).

The yellow Current Limit LED indicator light on the drive control board

illuminates when the armature current reaches 95-100% of the current limit setting.

Jog Speed (JOG SPD)

Adjust the JOG SPD pot clockwise to increase the speed (0-30% of full speed reference) at which the motor will run when in jog mode. It is factory preset to its full counterclockwise position.

Page 43

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. Since there are only two, one sets the time to change from (+)10vdc to (–)10vdc while the other sets the time to change from (-)10vdc to (+)10vdc. In essence, what this means is that the acceleration potentiometer sets the acceleration time in the forward direction and the deceleration time in the reverse direction and vice versa. The diagram below shows this graphically.

Time set by Acceleration potentiometer

Time set by Deceleration potentiometer

+10vdc Forward

-10vdc

Reverse

Fwd Accel

Fwd Decel

ccel

Time

Re Speed

Re Decel

Page 44

Basic Customer Adjustments

Acceleration

and

Deceleration

Time adjustments

JOG

SPEED

Sets Jog

Speed

MAX SPD

Adjust for maximum Motor speed

MIN SPD

Adjust for minimum Motor speed

Local Current Limit

Limits maximum Output Current

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” if the IR COMP pot is adjusted too far clockwise. If this pulsing of speed occurs, adjust the IR COMP pot counter clockwise until the motor speed stabilizes.

If JP4 is set in the TACH position indicated tachometer feedback is being used, turn the IR COMP pot fully counter clockwise otherwise instability will occur.

Note: If the drive is using the voltage or current signal follower, perform these adjustments with the Auto/Manual switch in the Manual position.

Velocity Stability (VEL STAB)

The VEL STAB pot helps match the dynamic characteristics of the drive to the dynamic characteristics of the DC motor and its load. The drive’s outer velocity loop includes an electrical “lead” circuit to compensate for the mechanical “lags” that exist in both the DC motor and its driven mechanical system. The VEL STAB pot adjusts the time constant of this lead circuit.

Clockwise rotation causes the drive to respond more quickly to speed command/speed feedback changes but increases the overshoot experienced by the drive. Counterclockwise adjustment of this pot dampens the drive response. It is factory preset at the midway position.

Current Stability (ISTAB)

The ISTAB pot matches the dynamic characteristics of the drive to the dynamic characteristics of the DC motor armature. The drive’s inner current loop includes an electrical “lead” circuit to compensate for the electrical “lag” that exists in the DC motor armature current. The ISTAB pot adjusts the time constant of this lead circuit.

In torque (current) control applications, the velocity loop is bypassed and the current loop is used. For speed (velocity) control applications, the current loop is fed from the output of the velocity loop.

The current loop responds to current changes quickly. Therefore, the ISTAB pot is very sensitive and harder to adjust properly. Clockwise rotation causes the drive to respond more quickly to current changes, but the factory shipped setting is usually adequate for most applications.

Speed Loop Offset (SPD OFFSET)

This pot is used to zero out any offsets in the speed loop amplifier. With the speed pot set to zero (as well as the Min Spd pot, if used), adjust the SPD OFFSET so any “creep” in the motor speed is eliminated with zero speed command. It is factory preset to its midway position.

Page 46

Additional Tuning Adjustments

Velocity Stability

(VSTB)

Adjust for speed loop

stability

IR Comp

Adjust for motor speed

droop due to load

Current Stability

(ISTB)

Adjust for current

loop stability

Speed Loop Offset

Adjust for zero creep

speed

Page 47

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.

The following 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; typically this selection is made by the

Auto/Manual selector switch (see page 31) .

Signal Follower Zero Bias (BIAS) used with Voltage Input (TB2-18)

The BIAS pot prevents “creep” in the motor speed by eliminating any unwanted offset voltage levels in the voltage source. It may also be used to add a slight offset to the voltage signal.

Signal Follower Zero Bias (BIAS) used with Current Input (TB2-17)

Adjust the BIAS pot so the drive is at zero speed when the minimum current signal follower speed command (0-20 or 0 –5 mA) is applied.

If a 4-20mA (or 1-5mA) speed command is required, use the optional signal

isolation board (F3NSBD). SEE Note on page 8

Voltage / Speed Signal Follower Gain (SP REF GAIN)

The SP REF GAIN pot calibrates the User supplied Voltage Signal Follower speed command (0 - 200 Vdc) so the motor reaches its rated voltage/speed when the input voltage signal is set to its maximum value. It is factory preset to its full counterclockwise position.

Current Signal Follower Gain (IREF GAIN)

The IREF GAIN pot calibrates the User supplied Current Signal Follower speed command ( 0-5mA or 0-20mA ) so the motor reaches its rated voltage/speed when the current signal is set to its maximum value. It is factory preset to its full clockwise position. SEE Note on page 8

Page 48

Optional Tuning Adjustments

Speed Rate

Zero Bias

Speed Reference Gain

Current Reference Gain

Page 49

Page 50

Page 51

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 F3R2E Drive Serial Number

F3R5E or F3R5E Drive Part Number _____________

a) AC Input Line Voltage 240 Vac

120 Vac

b) Motor Nameplate Information: Armature Voltage _________Vdc

Armature Current _________A Field Voltage _________Vdc Field Current _________A Rated RPM _________ rpm

c) Type of Speed Feedback Armature Voltage ( most common case )

DC Tachometer

Focus drives come to you factory set for Armature Voltage feedback. Even if your motor is equipped with Tachometer for Speed feedback, we would strongly suggest that you first run your motor using Armature Voltage initially. After you have set the motors maximum speed in Armature Voltage feedback, you can check your tachometers output to verify that it producing the correct output before actually using it.

d) Regulation Mode Speed ( most common case )

Torque ( read first ! )

Focus drives come to you factory set for Speed Regulation mode which is the most common case. Even if your application requires Torque control, we would strongly suggest that you first run your motor Speed Control initially. After you have verified

Page 52

proper operation in the Speed mode, you could then switch over to Torque mode.

Page 53

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

If Yes STOP The Focus 3 Field Supply rectifier will be damaged!!!

Call Tech Support for a solution.

STEP 3 If your motor field voltage is 100 Vdc,

then you must use 120 Vac for Input Power ----- Set JP11 as shown

and Set JP8 to Low

then go to STEP 7

If you must use 240 Vac ----- Call Tech Support for a solution otherwise go to STEP 4

: :

STEP 4 If your motor field voltage is 200 Vdc, then you must use 230 Vac for Input Power ---- Set JP11 as shown

and Set JP8 to Hi

then go to STEP 7

otherwise STOP ---- Call Tech Support for a solution

STEP 5 If your motor armature voltage is greater than 110 Vdc,

then you should use 230 Vac for Input Power ---- Set JP11 as shown

and Set JP8 to Hi

then go to STEP 7

If you must use 120 Vac ---- Call Tech Support for a solution

otherwise go to STEP 7

STEP 6 If your motor armature voltage is less than 110 Vdc,

then you must use 115 Vac for Input Power ----- Set JP11 as shown

and Set JP8 to Lo then go to STEP 7

: :

Page 54

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 DC Output Current JP9

Number (A) Jumper Position

2.6 No Jumper

(1/4 – 2 HP) 5.5 A

F3R2C 7.5 B F3R2E 10 C

then go to STEP 8

STEP 7a

Are you applying a Focus Model F3R5C or F3R5E? 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 7

FOCUS Catalog DC Output Current JP9

Number (A) Jumper Position

5.2 No Jumper

(3 – 5 HP) 11 A

F3R5C 15 B F3R5E 20 C

25 D

Page 55

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. When considering Operator safety the Installer must include and employ additional equipment to provide safeguards to insure Operator safety.

Consult all NEC and OSHA machine safety recommendations and guidelines.

These safeguards are the sole responsibility of the Installer. For these reasons, the Installer must envision all, implement all and test or simulate all failure methods. The Installer is responsible for his/her resulting implementation to insure safe and reliable operation of the installation.

In addition, the Installer should provide the End User of his Installed system with a System User’s Manual and instruct the User/Operator on correct/safe operation. Instruction should include the demonstration and purpose of safety features that you the Installer has included and the importance of periodic testing to insure they do indeed operate as designed. The Installer should instruct, inform and warn his End User customer against bypassing the safety permissives the Installer has provided.

NOTE: Without the use of the Contactor option, P/N 2400-9001 (or the Reversing

Contactor option, P/N 2400-9002, if reverse is required) potential motor movement in the

event of a power line disturbance (causing an SCR (power device) to misfire) can occur since the motor is connected directly to the power circuit even when the drive is disabled. It is highly recommended that one of these contactor kits be used to guard against such occurrences.

Page 56

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.

Installation of Option Kits

Do not install option kits until you have verified the basic operation as outlined in the

Start-Up section.

Page 57

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.

a) Type of Speed Feedback; In this procedure, leave jumper in armature

feedback (JP4 = ARM).

b) Regulation Mode: In this procedure, leave jumper in speed regulation

(JP2 = SPD).

For Chassis Units Only

ADD THIS

Add this

JUMPER

Jumper

Stop

Start

Speed Pot

Enclosure Cover

close to run

Drive run enable

Jog enable

+10vdc

FOCUS 3 Chassis Unit

Jog ref 0 to 30%

Regen only

A+

A-

F+

F-

FE1

FE2

For Enclosed Units Only

4 5

Drive run enable

FOCUS 3 Enclosed Unit

Regen only

A+

A-

F+

F-

FE1

FE2

Motor Armature

Motor Fiel

Note: Permanent Magnet Motors do not have Field F1 & F2, connections

Motor Armature

Motor Field

Page 58

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. Slowly adjust current limit pot clockwise (~1/4 turn) while watching motor shaft.

Verify that the motor rotates in the desired direction and that the motor slowly accelerates to about 30% of rated speed (also note that current limit light goes out when motor is running steady). If the motor rotates in the wrong direction, stop drive, REMOVE AC POWER and then reverse the field leads, F1 and F2. Re-apply power and repeat this step.

4. Stop Drive and Turn off AC Power.

Basic Setup with Tachometer Feedback

(go to step #8 if NO tachometer)

5. The drive can now be set up for tachometer feedback if required.

Set JP4 to “Tach” position Connect tachometer signal to drive (- to #19, + to #20) Set JP8 to “Hi” if the following calculated voltage is in the range 60 to 160 Vdc. Set JP8 to “Low” if the following calculated voltage is in the range 6.5 to 17.4 Vdc. Tach voltage at max speed = tach volts per 1000rpm X max motor rpm

1000

If the calculated voltage is NOT in the ranges listed above, consult factory.

Repeat steps 1 to 2 above then proceed to step 6.

6. Slowly adjust current limit pot clockwise (~1/4 turn) while watching motor shaft.

Verify that the motor rotates in the desired direction and that the motor slowly accelerates to about 30% of rated speed (also note that current limit light goes out when motor is running steady). If the motor continues to accelerate past ~30% speed, tachometer is probably connected backwards. Stop drive, Turn off AC POWER and then reverse the tachometer leads, re-apply power and repeat this step. Stop Drive and Turn off AC Power when complete.

7. 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.

Page 59

8. 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.

Basic Setup for Current (Torque) Regulator

9. If the drive is to be set-up as a Current (torque) Regulator, set jumper JP2 to

“CURR” position and JP4 to “TACH” position but DO NOT connect a Tachometer.

The standard speed command input (TB2-#10) is now the drive current reference. The accel / decel adjustments on the control board will now control the rate of change of current.

Note that the drive is now controlling motor torque and NOT speed, therefore if the current reference is set to a higher level than the torque required by the load,

the motor will run to speeds in excess of rated motor speed. In applications where this over-speed condition can occur (such as a web break in a simple re-winder) an external over-speed protection device must be added to the system.

Page 60

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. In addition, some common sense maintenance needs to be followed.

MAKE SURE THAT ALL POWER SOURCES HAVE BEEN DISCONNECTED BEFORE MAKING CONNECTIONS OR TOUCHING INTERNAL PARTS. LETHAL VOLTAGES EXIST INSIDE THE CONTROL ANYTIME INPUT POWER IS APPLIED, EVEN IF THE DRIVE IS IN A STOP MODE. A TURNING MOTOR GENERATES VOLTAGE IN THE DRIVE EVEN IF THE AC LINE IS DISCONNECTED. EXERCISE CAUTION WHEN MAKING ADJUSTMENTS WITH THE CONTROL DRIVING A MOTOR. NEVER INSTALL OR REMOVE ANY PC BOARD WITH POWER APPLIED TO THE CONTROL

KEEP IT CLEAN: The control should be kept free of dust, dirt, oil, caustic

atmosphere and excessive moisture.

KEEP IT COOL: The control should be located away from machines having a

high ambient temperature. On panel mount controls, air flow across heatsinks must not be restricted by other equipment within the enclosure.

KEEP CONNECTIONS The equipment should be kept away from high vibration TIGHT: areas that could loosen connections or cause chafing of

wires. All interconnections should be re-tightened at time of initial start-up and at least every six months.

THE DC MOTOR MAY BE AT LINE VOLTAGE EVEN WHEN IT IS NOT INOPERATION. THEREFORE, NEVER ATTEMPT TO INSPECT, TOUCH OR REMOVE ANY INTERNAL PART OF THE DC MOTOR (SUCH AS THE BRUSHES) WITHOUT FIRST MAKING SURE THAT ALL AC POWER TO THE CONTROL AS WELL AS THE DC POWER TO THE MOTOR HAS BEEN DISCONNECTED.

The motor should be inspected at regular intervals and the following checks must be made:

A. See that both the inside and outside of the motor are not excessively dirty. This can

cause added motor heating, and therefore, can shorten motor life.

B. If a motor blower is used, make sure that the air passages are clean and the impeller

is free to rotate. If air filters are used, they should be cleaned at regular intervals or replaced if they are disposable. Any reduction in cooling air will increase motor heating.

C. Inspect the commutator and brushes. Replace the brushes if needed. Make sure that

the proper brush grade is used.

D. The motor bearing should be greased per the manufacturer’s instructions as to type

of grease and maintenance frequency. Over greasing can cause excessive bearing heating and failure. Consult the instructions supplied with the motor for more details.

Page 61

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. Study the system instruction manual and control drawings. B. Obtain practical experience during the system installation and in future servicing. C. Train in the use of test instruments.

Maintenance Records

lt is strongly recommended that the user keeps records of downtime, symptoms, results of various checks, meter readings, etc. Such records will often help a service engineer locate the problem in the minimum time, should such services be required.

General Troubleshooting

The most frequent causes of drive failure are:

A. Loose or broken wire connections.

B. Circuit grounding within the interconnections or the power wiring.

C. Mechanical failure at the motor.

DO NOT make adjustments or replace components before checking all wiring. Also monitor all LED indicator lights before proceeding with troubleshooting checks, and check for blown fuses.

lt should be noted that modern solid state electronic circuitry is highly reliable. Often problems, which appear to be electrical, are actually mechanical. It is advised that the motor be checked in the event of any drive problems. Refer to the motor owner’s manual for maintenance and repair procedures.

Notes for a Troubleshooting Technician

A minimum knowledge of system operation is required, but it is necessary to be able to read the system schematics and connection diagrams.

An oscilloscope may be needed to locate problem areas and to make adjustments. However, the majority of problems can be solved by using a multimeter and by parts substitution.

WHEN A TEST INSTRUMENT IS BEING USED, CARE MUST BE TAKEN TO INSURE THAT ITS

CHASSIS IS NOT GROUNDED EITHER BY A GROUNDING PLUG CONNECTION OR BY ITS CASE BEING IN CONTACT WITH A GROUNDED SURFACE. EXTREME CARE MUST BE

TAKEN WHEN USING THE OSCILLOSCOPE SINCE ITS CHASSIS WILL BE ELECTRICALLY

Page 62

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:

A. Terminals TB2-1 and –2 on the main PC board not jumpered together - install either

a jumper or the Motor Thermostat between these terminals. B. No AC power - apply AC power and measure L1 and L2 for correct voltage. C. Blown line fuses - replace line fuses. D. Loose connections -turn off AC power and tighten connections. E. Control incorrectly wired - recheck all wiring. F. Defective Start/Stop switch, component on main PC board, or rectifier cube replace bad components as required. ( See Critical Components )

G. Speed potentiometer set to zero - slowly advance from zero to begin motor rotation.

LINE FUSES BLOW OR MAIN CIRCUIT BREAKER TRIPS WHEN APPLYING AC POWER:

A. Control is wired to AC voltage exceeding control rating -rewire control to proper AC

voltage or use step-down transformer.

B. Rectifier cube, field diodes on main PC board, motor winding or suppressor network

shorted, or a short to ground is present - locate and remove short.

C. Improper wiring or jumper programming during installation. D. Defective main PC board component - replace as required. (See Critical

Components )

E. Motor shaft jammed - determine cause and correct. F. Excessive carbon dust from brushes in motor - determine cause and correct.

FUSES BLOW WHEN SPEED POTENTIOMETER IS ADVANCED FROM ZERO:

A. Motor is overloaded - reduce load as required. B. Motor is defective - consult motor instruction manual and repair or replace motor

as required.

C. Current limit adjustment set too high - readjust

ACCEL TIME IS MUCH LONGER THAN EXPECTED:

A. Check Accel pot setting B Motor overloaded – reduce or remove load and re-check

DECEL TIME IS MUCH LONGER THAN EXPECTED:

A. Check Decel pot setting B. Motor is being overhauled by another motor in system or by inertia of the machine

MOTOR DOES NOT REACH FULL SPEED:

A. Motor is overloaded - correct overload condition. B. Maximum Speed potentiometer (MAX) is set too low -adjust MAX potentiometer

clockwise.

C. Low AC line voltage (more than 10% below nominal) -check AC line voltage and

correct. D. Current limit set too low – re-adjust. E. Incorrect jumper programming of JP9 - follow programming procedure

F. Defective rectifier cube - replace as required. (See Critical Components )

Page 63

Motor brushes worn - replace as specified in motor instruction manual.

Page 64

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. IRCOMP potentiometer is set too low - adjust clockwise H. Motor is overloaded - correct overload condition. I. Incorrect jumper programming – check jumpers. J. Defective component on main PC board – replace (See Critical Components) K. Current limit set too low – readjust. L. Motor brushes worn - replace as specified in motor instruction manual.

MOTOR DOES NOT COME TO FULL STOP:

A. Minimum Speed potentiometer (MIN) is set too high -readjust B. Defective speed or torque potentiometer, component on regulator PC board, Start/Stop switch, or rectifier cube -replace as required. (See Critical Components)

NO SPEED CONTROL:

M. Defective rectifier cube - replace as required (See Critical Components) N. Defective component on main PC board - replace as required. (See Critical

Components )

O. Incorrectly wired or defective speed potentiometer - check the wiring. P. Incorrect jumper programming - check jumper programming. Q. If the control (after rechecking all the wiring for proper and secure connections) is

still inoperative, make the following voltage checks. Double check to make sure that

armature leads Al and A2 are not grounded.

F. High resistance ground on motor armature

VOLTAGE CHECK CHART

Step Function

Normal Voltage Readings

with AC

Voltage to

Rectifiers

120 Vac 240 Vac ±10% ± 10%

Power “on”

Speed

0 to +10 0 to +10 Vdc Vdc

command

3 Field Supply

100 Vdc 200 Vdc

Voltage

4* Armature

0-90 Vdc 0-1 80 Vdc

Voltage

*Depends on the setting of the speed adjustment knob

Terminal

or Point

ACl AC2 On power cube

10-12

+Fl

-F2

+Al

-A2

Probable Cause

Blown Fuses

Defective speed adjustment potentiometer or circuit board assembly

Defective field diodes defective encapsulated bridge rectifier assembly

Defective encapsulated

bridge rectifier ass’y, or

circuit board assembly

Page 65

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. One could use a 75 watt light bulb screwed into a light bulb socket base as shown below.

Basic Test Power Wiring

In order to test the Focus, one would need to setup the input for 115 Vac operation and for basic Armature Voltage feedback. The drive should also be set for the lowest current setting. Therefore before testing, one should record the settings before test so that they could be reset back after the test.

Page 66

115VAC

Line Input

75 W

Record Drive Set-up BEFORE performing Light bulb test

Before Test

Circle One

JP2 SPD CUR

JP4 ARM TACH

JP8 Hi Low

JP9 A B C D

: :

115 Vac 230 Vac Operation

Test

JP2 SPD

JP4 ARM

JP8 Low

JP9 None

: :

115 Vac 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. One could measure the voltage across the bulb and it should be about 90 Vdc at maximum brightness. This would verify the basic Start/Stop, Speed command, Power Supply, Regulator and Power Sections.

Field Supply Checkout

If one wants to check the Field Supply, power should be removed and the light bulb moved over to the F+ and F- terminals (use a 75 W bulb or less for the field. Use of

greater than 75 W could permanently damage the Field rectifiers). Then upon

application of power, the light bulb should light to full brightness and the voltage across the light bulb should measure about 100 Vdc.

If the Focus passes these basic tests, the drive should be OK and the drive

should be able to run a good motor at least in Armature Voltage feedback (JP4 in ARM). Reset jumpers back to the “Before Test Recorded Settings” except for JP4 and re- check.

If the motor has a shunt field, it should measure at least:

200 ohms if Nameplate indicates 200 Vdc Field 100 ohms if Nameplate indicates 100 Vdc Field

Page 67

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.

1. 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. The chassis versions of the Focus 3 drives are slightly larger the Focus 2 drives unless the Focus 2 drive was supplied with the contactor option where as they are equivalent in size.

10.19

Focus 2 2 HP & 5HP Contactor Option Mounting Plate

1.25

14.24

9.75 9.35

Focus 2 2 HP & 5HP Enclosed Units

Focus 3 2HP Chassis & Enclosed Units

6.35

6.75

6.25

9.00

13.00 12.00

Focus 2 2 HP & 5HP Chassis Units

9.73

10.38

Focus 3 5HP Chassis & Enclosed Units

8.88

9.50

14.12

2. Power and signal connections:

Focus 2 – Power and Motor Connections across the top

Signal Connections down the left side

Focus 3 - Power and Motor Connections across the bottom

Signal Connections down the right

Page 68

3. 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 2Focus 3

Stop

Speed

Potentiometer

Remote Current Limit (If used)

DC Tachometer Only

Start

Manual

Auto

Motor Thermal

Run

Jog**

Fwd

Rev

(-)

(+)

+24

Tie Point

Run Input

Run Run

Jog Input

Jog Pot Supply

+10 Vdc

Speed Ref.

-10 Vdc

Signal Common

Min Spd Pot

Remote Current Limit Input

Auto/Manual Input

Current Source Input

Voltage Source Input

Tach

Input

Tie Point

Run Input

Jog Input

+10 Vdc

Speed Ref.

Min Spd Pot

Signal Common

Tach

Input

+24

Motor Thermal

Stop

Start

Run

Jog**

(-)

(+)

Speed

Potentiometer

DC Tachometer or AC Tachometer

Note: Fwd / Rev switch connected to reversing board, not shown

Page 69

4. 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) and kit Instruction Sheets (CTISXXX) are posted on our web site

These documents provide a wide variety of information instantly available day or night. Below is a list of currently available Application Notes :

Click on DC Drives if on website

Application

Drive

Family Topic

Note #

CTAN 125 A Focus 3 Replacing Focus 2 with Focus 3 Drives CTAN 130 1.1 Focus 3 Tach Follower Applications CTAN 204 1.0 Focus 3 Power Wiring Guidelines CTAN 213 1.1 Focus 3 Eddy Current Controller Retrofit CTAN 215 1.0 Focus Family Earth Grounding & Isolation CTAN 216 1.0 Focus 3 Eddy Current Replacement Solution CTAN 235 1.0 Focus 3 Adjustable Brake / Dynamometer App’s CTAN 240 1.0 Focus 3 Speed Master w/Torque Slave CTAN 241 1.0 Focus 3 120vac Remote Control Pushbuttons CTAN 243 1.0 Focus 3 Multiple Drives Running in Tandem CTAN 244 1.0 Focus 3 Isolated Master Reference Board

Replacement Instruction for Control Board (CTRI1210) can be found at our website at:

www.emersonct.com or click the link below:

CTRI210

CTAN130 and CTAN 215 are given in the next few pages.

Page 71

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 second drive as a speed command. A disadvantage to the parallel method is that if for some reason the first drive slows down while in a current limit condition, for example, the second drive would no longer follow since it may not be in a current limit condition. This is not the case for the cascaded method since the drive is following the actual speed of the first drive.

Maste

Focus Isolator

Focus 3 Drives

The Focus 3 isolator option (p/n F3NSBD) is ideally suited for this purpose since it is powered directly by the Follower drive and connections are minimal. For additional information go to the following link :

http://www.emersonct.com/download_usa/manuals/Kits/2415-3050.pdf

(F3NSBD)

Followe

Page 72

Page 73

4 5

Drive run enable

A+

A-

F+

F-

FE1

FE2

Regen only

Motor Armature

FOCUS 3

Stop

Start

Speed Pot

Motor Thermal

Manual

Auto

(-)

(+)

4 5

Drive run enable

A+

A-

F+

F-

FE1

FE2

Regen only

Motor Armature

Motor Field

FOCUS 3

Stop

Start

Speed Pot

Motor Thermal

Manual

Auto

(-)

(+)

TB2

Isolator Board P/N 2415-4050

TB1

TB2

(+)

(-)

+24vdc Input

Common

Output

Motor Field

TB2

Focus 3 Regen Master / Follower Application

Page 75

Critical Components and Replacement Parts

Main Control Board

Terminal Strips

13Pin 3470-50013

7 Pin 3470-50007

6045-4000 F3R2C & F3R2E

Speed Adjust Pot

3533-0502 – Potentiometer

3549-002 - Knob

3550-005 Start / Stop Switch

6045-4005 F3R5C & F3R5E

Fuses

3701-506000

60 A, 500 Vac

Fuses

3705-032

15 A, 250 Vac

Power Block

3720- 4X2F

All Focus 3 Regens

These components are stocked and sold through the North American Service Center. To order please contact Parts Dept @ 1-800-367-8067

Page 76

INDEX

Adjustments · 2, 3, 20, 40, 43, 44, 45, 46, 47

Accel/Decel · 59 Current Limit · 8, 11, 26, 39, 55, 65 IR Comp · 11 Jog Speed · 11, 65 Potentiometers · 40 Stability · 11, 44

Tuning · 3, 44, 45, 46, 47 Application Notes · 3, 66 Auto Manual · 8, 12, 26, 44, 46

Chassis Model · 4, 9, 10, 11, 12, 13, 28 Contactor Kit · 6, 11, 12, 34 Control Wiring · 3, 20, 22, 25 Current Control · 34, 35, 66 Current Limit · 8, 11, 26, 39, 55, 65

DB · 6 Dynamic Braking · 6

Eddy Current Controller · 66 Enclosed Model · 4, 9, 11, 12, 14, 28, 65

Jumper Settings

Current Limit · 8, 11, 26, 39, 55, 65 Current Ranges · 3 Line Voltage · 34, 50

Jumpers · 3, 20, 34, 35, 36, 37, 51, 52

Kits

Installation · 2, 3, 12, 15, 16, 17, 22, 53 Option Kits · 2, 3, 6, 15, 16, 17, 22, 53

LED Indicators · 3, 39, 58

Current Limit · 8, 11, 26, 39, 55, 65

Model

Chassis · 4, 9, 10, 11, 12, 13, 28 Enclosed · 4, 9, 11, 12, 14, 28, 65

Motor

Compatibility · 2, 5, 64 Permanent Magnet · 5, 6 Shunt Wound · 5, 6, 21, 22 Wiring · 2

Field

Current · 5, 50 Field

Voltage · 50 Focus 1 · 4 Focus 2 · 3, 4, 63, 64, 65, 66 Fusing · 8, 21

Input

Line Voltage · 34, 50 Installation

Kits · 12 Isolation · 3, 12, 66 Isolaton · 3, 12, 66

Nema Rating · 4, 9, 10, 11, 12, 14, 65 Non-Regenerative · 3

Option

Kits · 2, 3, 6, 15, 16, 17, 22, 53

Power

Requirements · 2, 21 Wiring · 3, 20, 23, 24, 61, 66

Ratings · 2, 10 Regenerative · 65

Page 77

Spare Parts · 3

Critical Components · 59, 60, 70 Specifications · 2, 10 Speed Command

4-20mA · 8, 46 Speed Control

Armature Voltage Feedback · 2, 6

Speed Pot · 3, 12, 26, 28

Tachometer Feedback · 11, 22, 34, 55 Start-Up · 2, 3, 20, 22, 53, 54, 55 Stopping

Quick Stopping · 2, 6

Terminals · 28, 29, 30, 31, 32, 46, 59, 60 Torque Control · 3, 8, 11, 35, 50, 56 Troubleshooting · 58 Tuning

Stability · 11, 44

Wiring

Control · 3, 20, 22, 25 Motor · 2 Power · 3, 20, 23, 24, 61, 66

Page 78

Control Techniques Focus 3R User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual