Control Techniques Emerson Focus 1 User manual

Page i
User Guide
P/N: FOCUS1-UG
Revision: A1
Date: Feb 10, 2005
© Control Techniques Drives, Inc. 2005
Focus 1
¼ to 2HP Single Phase,
Uni-Directional
Non-Regenerative
DC Drive

Page ii
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.
All rights reserved. No parts of this User Guide may be reproduced or transmitted in any
form or by any means, electrical or mechanical, without permission in writing from
Control Techniques.

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Customer Support
Control Techniques
359 Lang Boulevard, Building B
Grand Island, New York 14072
U.S.A. Telephone: [phone]
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 [phone]
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: [email protected]
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 [phone] or [phone]
Email: [email protected]
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 [phone] or [phone]
Email: [email protected]
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 iv
“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 v
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, non-
conducting 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.

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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 7
Table of Contents
Topic Page
Introduction 9
Motor Compatibility 10
Basic Control Modes/Feedback 12
Armature Voltage Feedback 12
Quick Stops 12
Receiving, Inspection, Storing 13
Performance Features 14
Nameplate Information 15
Nameplate Location 15
Catalog Number Definition 16
Specifications
Ratings Table 16
Performance Specifications 17
Operating Conditions 17
Internal Adjustments (Potentiometer) 17
Customer Selections (Jumpers) 17
Operator Functions 18
Control Circuit Specifications 18
Options 18
Dimensions 19-20
Option Kits & Descriptions 21-24
Customer Connections & Start-Up
Start-Up Guidelines 26
Incoming Power Requirements 26
Grounding 26
Motor Wiring 26-27
When viewing this document electronically, the Table of Content items are active and
will direct you to that topic by clicking on that item.

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Table of Contents
Topic Page
Power Wiring 28
Control Wiring 29-31
Speed Pot Wiring 32
Customer Selections
Jumper Programming 34-38
Current Ranges 35
Current/Torque Control 36,48
LED Status Indicator 37
Potentiometer Adjustments 38-40
Basic Adjustments 38-39
Tuning Adjustments 40
Interconnect Drawings
Functional Block Diagram 47
Circuit Overview 48
Start-up Guide Worksheet 41-43
Application Safety 44
System Interface Suggestions 45
Initial Start-Up & Basic Test Setups 46
Installation of Option Kits 46
Motor Test 53-55
Trouble Shooting Guide 49-56
Oscilloscope Safety 51
Light Bulb Test 57-58
Application Notes 59
Drive Isolation 60-62
Spare Parts 63
When viewing this document electronically, the Table of Content items are active
and will direct you to that topic by clicking on that item.

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Introduction
This is the User’s Guide for Focus 1 (Non-regenerative) series of DC Drives. The Focus
1 is a 2nd generation product of the long-standing Focus series. The Focus 1 was introduced
back in 1980. The Focus 1 non-regen drive remains as a popular single-phase, uni-directional
analog drive for DC motors with power ranges from ¼ to 2HP.
Your Focus 1 is a general purpose non-regenerative DC motor speed controller that is
powered from either 115Vac or 230Vac single phase power. A non-regenerative (single
quadrant) drive is one that can provide motoring torque for acceleration and to overcome rated
loads. There are a great many applications where non-regenerative drives provide the most
economical solution. A non-regenerative drive however cannot slow down a motor faster than
the motors normal coasting rate (unless a Dynamic Braking stop is commanded) nor can it stop
overhauling load situations. For more demanding applications, a sister drive- the Focus 3
Regen (regenerative model), offers full four quadrant operation for bi-directional motor control
and controlled deceleration as well as opposition to overhauling loads.
Focus 1 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.
Enclosed Model
The Enclosed version comes to you already in a NEMA 1
enclosure that would allow the User to mount the Focus on a
wall or machine surface. The Enclosed version has Power
On/Off Switch, a spring to center Start/Stop switch and the
Speed Control adjustment right on the front cover for
convenient operation. For additional environmental
protection, a NEMA 4/12 option kit is available.
For a complete overview of the Focus 1 product
line and available options, visit our website at:
www.emersonct.com or click the link below:
Focus 1 Catalog Section

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1 1750 / 2050 180
5.0 SHUNT
0.28/.22 518
FLD VOLTS 200/100
Motor Compatibility
The Focus 1 was designed to run standard 90 Vdc or 180 Vdc Shunt Wound or Permanent
Magnet DC motors in one direction. The Focus 1 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
direction cannot be reversed.
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 1 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
1 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
1 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.
240v Armatures typically require 150 Vdc for field excitation. In these cases, the Focus
1 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.

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Motor Compatibility
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-. The Focus 1 is compatible
with most all PM motors having either 90v or 180v armatures.
Armature
Voltage
Armature
Current
Permanent
Magnets

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Speed Control
Armature Voltage Feedback
The Focus 1 varies 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). 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.
Quick Stops
A non-regenerative drive cannot stop a motor faster than the motors normal coasting
rate unless a Dynamic Braking resistor is employed. 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 1 can be outfitted with a Dynamic Braking resistor should
this requirement be desired.
Note: DB Resistors require Contactor Option - See Options
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 but this should be tested from full
speed to determine if power outage stopping time is sufficient should this factor be a
safety consideration for your application.
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.

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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 1 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. See page 15 for
nameplate location.
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
r
standard safety precautions should be permitted to install, start-up, or maintain this
apparatus.

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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.
•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
•Current (Torque) Regulator -
2% accuracy armature current regulator allows the user to control motor torque instead of
speed.
•Circuit Board Indicator – A Light emitting diode (LED) on the control board indicate when
the drive is active in the Run Mode.
•
•UL/cUL - All Focus 1 Drives are UL/cUL listed.
•One cannot make a connection to ground or a grounded device to any terminal o
r
connection point to the Focus 1 Non-Regenerative Drive without causing driv
e
damage. Such failures unfortunately cannot be warranted.
•See Ways of Achieving Isolation on page 60 of this manual

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The Focus 1 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 Model
The Enclosed version comes to you already in a NEMA 1 enclosure that would allow the
User to mount the Focus on a wall or machine surface. The Enclosed version has a
Power On/Off and spring to center Start/Stop switches and the Speed Control
adjustment on the front cover for convenient operation.
Nameplate Information
Enclosed Unit
Chassis Unit
Part # Serial #
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 #41.
P/N 2400-8001
5507051

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Specifications
Ratings
AC Input DC Output
Catalog Enclosure HP 1Ø Max Armature Armature Field Field
Part # Volts Amps Volts Amps Volts Amps
2400-
8001W
Chassis ¼ -1
½-2
120
240
14
14
90
180
10
10
100
200
1
1
2400-
8000W
NEMA 1 ¼ -1
½-2
120
240
14
14
90
180
10
10
100
200
1
1

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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
Speed Range: 30:1
Efficiency:
Control Only 98%
Drive System (motor and control) 86% typically
DRIVE OPERATING CONDITIONS
Altitude (without derating) 3300Feet or 1000meters
Ambient Temperature:
Chassis Models 0-550C (32 to 130° F )
Enclosed (NEMA 4/12) 0-400C (32 to 104° F )
INTERNAL ADJUSTMENTS (POTENTIOMETERS)
Potentiometer Function Range
Maximum Speed 70-115% of Rated Speed
(~60vdc-105vdc w/120vac input)
(~120vdc-210vdc w/240vac input)
Minimum Speed 0-30% of Maximum Speed
IR Compensation 0-20% of Rated Voltage
Internal Factory Settings
Current Limit Fixed at 150% of Selected Range
Acceleration Time Fixed 2-3 seconds (linear)
Deceleration Time Fixed 2-3 seconds (linear)
CUSTOMER SELECTIONS (JUMPERS)
Function Range
Input Voltage 120/240Vac
Control Mode Speed / Torque
Current Feedback range High / Medium / Low
Armature Voltage level 90 Vdc/180 Vdc
Optional “M” Contactor Yes/No

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OPERATOR FUNCTIONS
Chassis Enclosed
Speed Adjustment (Speed Pot) Standard Standard
Start/Stop Customer Supplied Standard
Forward/Reverse Optional Optional
CONTROL CIRCUIT SPECIFICATIONS
Logic Control Power 24 Vdc
Speed Potentiometer 5000 ohms
Input Signal Requirement 10 Vdc @ 0.2mA (44Kohm input resistance)
Control Circuit Isolation Optional
FOCUS 1 OPTIONS
CATALOG
NUMBER DESCRIPTION
2400-9001 M-Contactor Kit
F3DB124 Dynamic ¾ -1HP @ 240V
F3DB0524 Braking ½ HP @ 240V
F3DB112 Kits ¾ -1HP @ 120V
F3TS Toggle Switch, NEMA 4 /12
F3NSBD Signal Isolation Board
2950-9066 Remote OperatorStation ( 3 Function )
2950-9068 Remote OperatorStation ( 5 Function )
6160-9001 Ten-Turn Precision Potentiometer
Remote Percent Speed Meter Kit

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Focus 1 Chassis Dimensions
Chassis
Suitable for mounting in a user’s enclosure where internal temperatures will not exceed
550C or 1300F.
2400-8001W

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Focus 1 Enclosed Dimensions
NEMA 1
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
(104 0F).
Depth 5 inches maximum
2400-8000W