Control Techniques Focus 3R User manual

Page i
Focus 3R
¼ to 5HP Single Phase
Bi-Directional
Regenerative DC Drive

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

Page iii
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.

Page vi
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 2
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.

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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.

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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

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1 1750 / 2050 180
5.0 SHUNT
0.28/.22 518
FLD VOLTS 200/100
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.
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.

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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

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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.
Note: DB Resistors require Contactor Option - See Options
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.

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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 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
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.
•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.

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The Focus 3 comes in two basic model variations- with and without enclosure.
Chassis Model
The model without an enclosure is denoted as a chassis model. The chassis model is
intended for mounting within a User supplied cabinet and where the User intends to
provide remote Start/Stop and Speed control signals.
Enclosed 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.
Nameplate Information
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.
Enclosed Unit
Chassis Unit
Model # Part #
Serial #
Model Number Definition
F3 N 2 C
Enclosure
Chassis (C)
Enclosed (E)
Max HP Rating @240vac
2 HP (2)
5 HP (5)
Non-Regen (N)
Regen (R)
Drive Family
Focus 3 (F3)

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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
F3R2C Chassis ¼ -1
½-2
120
240
14
14
90
180
10
10
100
200
1
1
F3R2E NEMA 4/12 ¼ -1
½-2
120
240
14
14
90
180
10
10
100
200
1
1
F3R5C Chassis 3-5 240 35 180 25 200 1
F3R5E NEMA 4/12 3-5 240 35 180 25 200 1
F3R5C
F3R2C
F3R2E
F3R5E
Chassis Models
Enclosed Models

Page 12

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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
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

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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 OperatorStation ( 3 Function )
2950-9068 Remote OperatorStation ( 5 Function )
6160-9001 Ten-Turn Precision Potentiometer