Hubbell 4015 User Manual

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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

Time-provendc dynamic lowering hoist circuit.

High-speedhoisting 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-phasewye-connectedsecondary.

The rectifier unit is a three-phasefull 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, andfront-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-closedcontactor 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-phasedelta primary andthree-phasewye secondary (for separate mounting by customer).

1 — Three-phasefull 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 has2—2½%taps above and below the nominal voltage rating. A 3- phase wye secondary connection is used.

RECTIFIER

A 3-phasefull 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-ratingthe 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

 

• 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 load-hoistingspeed.

 

 

 

 

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 50-tonload 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 =

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, 200-hpac 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-hpdc 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-hpdc 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.

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) 434-2800• FAX (336)434-2803

http://www.hubbell-icd.com

Sales@hubbell-icd.com