Hubbell 4015 User Manual
Hubbell Industrial Controls, Inc.
TYPE 4015 RECTIFIED DYNAMIC LOWERING
SPECIFICATIONS
4015
May 2004
Repl.: January 1989
FOR HOIST SERVICE
All the advantages of a dc hoist controller on an
ac crane:
• Rugged dc series wound mill motor.
• Reliable dc series wound brake
• Time-proven dc dynamic lowering hoist
circuit.
• High-speed hoisting and lowering of empty
hook or light loads.
• Slow, stable hook speeds hoisting and
lowering with all loads.
• Reliable dc dynamic lowering with motor
connected as a generator and loaded with
the dynamic braking resistor.
• "Off point" braking because of springclosed dynamic braking contactor.
The complete hoist control system consists of a
power transformer, a silicon bridge rectifier and
the hoist controller with accessories.
• The power transformer is a totally
enclosed, nonventilated (TENV), threephase unit with delta connected primary
and a three-phase wye-connected
secondary.
• The rectifier unit is a three-phase full wave
bridge with diodes in parallel for
redundancy. Rectifier protection is
provided by fuses in each leg and a surge
suppressor and snubbing circuit on the dc
side. Output of the rectifier is 300V dc.
• The hoist controller is standard dc dynamic
lowering controller arranged for operation
from 300V dc power. The controller
components are all front-mounted, frontremovable, and front-wired.
A hoist control system with rectifier output of
360V dc is available as an option. Such a
system operates at higher speeds than the
300V dc system, resulting in a reduced duty
cycle time of about 15%.
Suitable for all NEMA and CMAA service
classes.
Recommended for: NEMA service Class I,
CMAA service Classes A1, C, D, E, F
MATERIAL LIST FOR TYPE 4015 SINGLE MOTOR CONTROLLER WITH PROTECTION
1 — Two pole main knife switch.
1 — Two pole fused control knife switch.
1 — Electronic overload relay with instantaneous and inverse time trip feature.
1 — 50mV ammeter shunt.
1 — Single pole main line contactor.
4 — Single pole directional contactors with mechanical interlocks.
1 — Single pole spring-closed contactor for dynamic lowering.
4 or 5 — Single pole accelerating contactors.
4 or 5 — Solid state "in-line" timers for acceleration.
2 — Voltage relays.
1 — Undervoltage relay
1 — Power transformer with three-phase delta primary and three-phase wye secondary (for
separate mounting by customer).
1 — Three-phase full wave rectifier bridge with current limiting fuses and surge suppressors.
APPLICATION DATA
TRANSFORMER
The power supply transformer is a totally enclosed
nonventilated, air-cooled, separately mounted transformer
with 480V, three-phase, 60 Hz primary; it has 2—2½%
taps above and below the nominal voltage rating. A 3phase wye secondary connection is used.
RECTIFIER
A 3-phase full wave connected rectifier circuit is used.
Each of the three phases contains two or more silicon
diodes, protective fuses and neon fuse failure indicators.
A voltage surge suppression network is included on the
rectifier.
RECTIFIER PANEL AND
TRANSFORMER RATINGS
The ratings shown are based on a maximum ambient
temperature of 40° C with the rectifier panel and
transformer supplied in standard, nonventilated
enclosures. Higher temperature ratings are attained by
either de-rating the equipment or by providing ventilation.
For applications involving ambient temperatures above
40°, consult the factory.
MOTOR HORSEPOWER SELECTION
In addition to the weight of the load being hoisted and the
desired hoisting speed, the hoisting cycle also affects the
motor horsepower selection.
COMPARISON OF BASIC CHARACTERISTICS
OF DC SERIES MOTOR AND
AC WOUND ROTOR MOTORS
DC SERIES MOTOR AC WOUND ROTOR MOTOR
• No load speed is approximately 2
or 3 times full load speed.
• When used with dynamic lowering
controller the motor can lower
rated load at a speed much greater
than the rated load-hoisting speed.
• Maximum motor speed increases
in proportion to increase in line
voltage.
• Increased speeds result in
increased horsepower without
change in motor size.
CRANE PERFORMANCE COMPARISON*
Control Type
Hoist full load
Lower full load
Hoist empty load
Lower empty load
Average
* 100% speed = ac motor synchronous speed or dc motor rated speed at 230 volts dc.
90% efficiency is assumed.
StandardACStandard
• Maximum motor speed limited to near
synchronous speed for no load and
full load.
• Maximum motor speed not affected by
increase in line voltage.
Standard
with 300V
96%
102%
99%
100%
99%
230V DC
100%
200%
212%
140%
149%
DC
130%
220%
250%
155%
175%
Optional
with 360V
DC
155%
240%
252%
180%
198%
SPECIFIED HOISTING SPEED EXAMPLE
Assume the hoist must lift a 50-ton load at a specific
speed of 45 feet per minute, a crane hoist motor is
selected on the basis of the following formula:
Payload & Hook Block Weight in Lbs. x
HP =
HP =
Desired Full load Hoisting Speed in fpm
33,000 x Crane Hoist Efficiency
100,000 Lbs. x 50 fpm
33,000 x .90
= 168 hp
Therefore, 200-hp ac motor would be required.
If a dc series motor of equal horsepower is selected and
used with the Type 4015 controller, it will hoist full load at
130% of rated motor speed:
HP (@ 230 vdc) = 168 hp/1.30 = 129 hp
Therefore, a 135-hp dc motor would be applicable.
DUTY CYCLE EXAMPLE
Assume that this same hoist must meet the following duty
cycle rather than a specific hoisting speed: (1) lower the
empty hook; (2) hoist full load or less; (3) lower full load or
less; (4) hoist empty hook.
Since the standard Type 4015 hoist control provides an
average hook speed of 175% as compared to the ac
motor control:
HP (@ 230 vdc) = 168 hp/1.75 = 96 hp.
A 100-hp dc motor could be used.
In other words, a dc series motor of equal horsepower as
its ac counterpart will complete the hoist cycle in about
half the time required by the ac motor.
Even greater performance can be obtained by increasing
the voltage to the motor to 360V dc. With the higher
voltage, the hoisting cycle described above can be
competed 198% faster than it could with an ac motor drive
of equal horsepower.
If the Type 4015 hoist control is applied on bucket or
magnet cranes, the minimum load consists of the weight
of the magnet or empty bucket. Only two (2) operating
conditions exist. The hoist cycle consists of hoisting full
load and lowering minimum load. When the average
speed is determined, the required 230V horsepower rating
for the dc series motor will usually vary from 65% to 70%
of its ac counter-part, depending on the minimum load
conditions.
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