Hubbell 4015 User Manual
SPECIFICATIONS
4015
May 2004
Hubbell Industrial Controls, Inc.
Repl.: January 1989
TYPE 4015 RECTIFIED DYNAMIC LOWERING
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
•
•
•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
•The rectifier unit is a
•The hoist controller is standard dc dynamic lowering controller arranged for operation from 300V dc power. The controller components are all
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
4 or 5 — Single pole accelerating contactors.
4 or 5 — Solid state
1 — Undervoltage relay
1 — Power transformer with
1 —
APPLICATION DATA
TRANSFORMER
The power supply transformer is a totally enclosed nonventilated,
RECTIFIER
A
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
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 
 • Maximum motor speed limited to near  
 or 3 times full load speed. 

 synchronous speed for no load and  
•  When used with dynamic lowering 
 full load. 

 



 
 controller the motor can lower 



 
 rated load at a speed much greater 



 
 than the rated 



 
•  Maximum  motor speed  increases 
 • Maximum motor speed not affected by  
 in proportion to increase in line 
 increase in line voltage. 
 
 voltage. 







•  Increased  speeds result in 



 
 increased  horsepower  without 



 
 change in motor size. 




 
CRANE PERFORMANCE COMPARISON* 
 






 Standard  Optional 



 Standard 
 Standard  with 300V  with 360V 
 Control Type 
 AC 
 230V DC  DC  DC  
Hoist full load 

 96% 
 100%  130%  155%  
Lower full load 
 102% 
 200%  220%  240%  
Hoist empty load 
 99% 
 212%  250%  252%  
Lower empty load 
 100% 
 140%  155%  180%  
Average 

 99% 
 149%  175%  198% 
*100% speed = ac motor synchronous speed or dc motor rated speed at 230 volts dc. 90% efficiency is assumed.
SPECIFIED HOISTING SPEED EXAMPLE
Assume the hoist must lift a
 Payload & Hook Block Weight in Lbs. x 

HP =  Desired Full load Hoisting Speed in fpm 

 33,000 x Crane Hoist Efficiency 

HP =  100,000 Lbs. x 50 fpm  = 168 hp 
 33,000 x .90 

Therefore,
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
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
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
ELEMENTARY DIAGRAM FOR HOIST CONTROL
TYPICAL CRANE PERFORMANCE CURVES TYPE 4015 DC DYNAMIC LOWERING CONTROL (RECTIFIED AC POWER) 300 VOLT DC
X = DENOTES CONTACTS CLOSED
CONTACTORS 1A AND L, K AND H, H AND J
ARE MECHANICALLY INTERLOCKED
DIMENSION DATA
SINGLE MOTOR CONTROL WITH PROTECTION APPROXIMATE DIMENSIONS AND WEIGHTS
(DO NOT USE FOR CONSTRUCTION PURPOSES)
CURVES ARE BASED ON AN ASSUMED HOIST DRIVE EFFICIENCY OF 80%
ENCLOSED CONTROL PANEL
Max HP 


 Net 
Crane Rating  H  W  D  Weight 
230 vdc 


 (lbs.) 
35  72  45  16  900 
55  72  45  16  900 
110  80  45  18  1100 
225  85  94  24  2000 
330  85  94  24  2100 
Panel modifications may change controller dimensions. Door swing is limited to 20" or less.
ENCLOSED RECTIFIER PANEL
Max HP 


 Net 
Crane Rating  H  W  D  Weight 
230 vdc 


 (lbs.) 
35  60  24  22  500 
65  60  24  22  500 
100  60  24  22  500 
135  60  40  22  800 
200  60  40  22  800 
330  72  50  22  1200 
Door swing is limited to 20" or less.
TRANSFORMER
Max HP 


 Net 
Crane Rating  H  W  D  Weight 
230 vdc 


 (lbs.) 
19  26  26  20  300 
35  28  27  20  400 
45  30  29  20  500 
65  36  35  24  600 
100  39  38  28  800 
135  48  47  30  1100 
200  51  48  30  1300 
265  53  50  35  1800 
NOTE: Transformer for 100 HP and above are floor mounted only.
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARD "Z" LENGTH RESISTOR
FRAMES (26.5" LONG)
 Horsepower  10  13½  19  26  33  45  65  100  135  200  265 















 NEMA Class 162 DL  5  5  6  8  10  12  17  21  30  43  53 















 NEMA Class 172 DL  7  7  9  11  14  17  24  30  42  60  74 





























Hubbell Industrial Controls, Inc.
A subsidiary of Hubbell Incorporated
4301 Cheyenne Dr., Archdale, NC. 27262
Telephone (336)