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September 2008 FRONTLINE
AC CRANE CONTROL
FRONTLINEreg AC CRANE CONTROL
AC CRANE CONTROLCONTENTS
DescriptionType M Contactors
EDDYMAGHoisthelliphelliphelliphelliphellipAC Dynamic Lowering HoisthelliphelliphelliphelliphellipCONTRA-TORQUE Hoisthelliphelliphelliphelliphellip
Reversing PlugginghelliphelliphelliphelliphellipDimensionshelliphelliphelliphelliphellip
Modifications and Applicationshelliphelliphelliphelliphellip
Type S ControlshelliphelliphelliphelliphellipDimensionshelliphelliphelliphelliphellip
Resistor SelectionhelliphelliphelliphelliphellipMaster Switcheshelliphelliphelliphelliphellip
Disconnect SwitchesManual Magnetichelliphelliphelliphelliphellip
AC CRANE CONTROL CLASS
AC CRANE CONTROLCONTENTS
Class Page
helliphelliphelliphelliphellip6420 helliphelliphelliphelliphellip 2-3helliphelliphelliphelliphellip6421 helliphelliphelliphelliphellip 4-5helliphelliphelliphelliphellip6422 helliphelliphelliphelliphellip 6-7helliphelliphelliphelliphellip6426 helliphelliphelliphelliphellip 8-9helliphelliphelliphelliphellip642126 helliphelliphelliphelliphellip 10-11helliphelliphelliphelliphellip642126 helliphelliphelliphelliphellip 23-25
helliphelliphelliphelliphellip6435 helliphelliphelliphelliphellip 12-15helliphelliphelliphelliphellip6435 helliphelliphelliphelliphellip 16helliphelliphelliphelliphellip6715 helliphelliphelliphelliphellip 17helliphelliphelliphelliphellip9004 helliphelliphelliphelliphellip 19
helliphelliphelliphelliphellip6440 helliphelliphelliphelliphellip 20-22
Class6420 64216422 64266435 6440May 2008
FRONTLINE
2
CLASS
GENERAL INFORMATION
Class 6420 reversing EDDYMAGreg controllers are recommended for use with ac wound rotor motors and eddy current electric load brakes oncrane hoist drives without mechanical load brakes All controllers are arranged for use with rectifier operated dc shunt braoperated ac brakes
The standard single motor reversing EDDYMAGreg controllerconsists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
LCB)2mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L)1mdashType M two-pole main contactor (M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)2 or 3mdashType ST1 static acceleration timers (3AR 4AR1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)1mdashPneumatic timing transition relay (TR)1mdashControl relay to detect loss of eddy current brake excitation
(ACDC)1mdashSet of static eddy current brake control equipment (ECBM)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashType SZF acceleration relay (5AR)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Voltage3Ǿ
5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current For These controllers have six speed points available but are used with fivediams These controllers have seven speed points available but are used with six
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONEDDYMAGreg
HOIST SERVICEcontrollers are recommended for use with ac wound rotor motors and eddy current electric load brakes on
crane hoist drives without mechanical load brakes All controllers are arranged for use with rectifier operated dc shunt bra
controller
t breaker with padlock clip
with mechanical interlock for
Type ST1 static acceleration timers (3AR 4AR 5AR)sformer
Control relay to detect loss of eddy current brake excitation
(ECBM)
PROVIDES SLOW HOISTING AND LOWERING SPEEDSFOR ALL LOADS
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 7001 TYPE ST1 STATIC ACCELERATION TIMERS REQUIRES EDDY CURRENT ELECTRIC LOAD BRAKE
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH70 DSH70 DWH705 EOH70 ESH70 EWH705 FOH70 FSH70 FWH705 GOH70 GSH70 GWH706diams GOH90 GSH90 GWH90
5 DOH70 DSH70 DWH705 EOH70 ESH70 EWH705 FOH70 FSH70 FWH705 GOH70 GSH70 GWH706diams GOH90 GSH90 GWH90
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application Dts available but are used with five speed point master switches the last acceleration point being relay controlled
but are used with six speed point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
controllers are recommended for use with ac wound rotor motors and eddy current electric load brakes oncrane hoist drives without mechanical load brakes All controllers are arranged for use with rectifier operated dc shunt brakes or solenoid
AND LOWERING SPEEDS
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
TYPE ST1 STATIC ACCELERATION TIMERSS EDDY CURRENT ELECTRIC LOAD BRAKE
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH70EAH70FAH70GAH70GAH90
DAH70EAH70FAH70GAH70GAH90
Controller Ratings section of Application Datapoint master switches the last acceleration point being relay controlled
ches the last acceleration point being relay controlled
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
EDDYMAG
FRONTLINEreg AC CRANE CONTROL
EDDYMAGreg HOIST ELEMENTARY
AC CRANE CONTROL
3
CLASS
FRONTLINE
4
CLASS
AC DYNAMIC LOWERINGGENERAL INFORMATION
Class 6421 reversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanicalload brakes All controllers are arranged for use with rectifier operated dc shunt brakes or solenoid
The standard single motor reversing dynamic loweringconsists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)4mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L DB M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)3 4 or 5mdashType SZF static acceleration relays
(2AR 3AR 4AR 5AR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)1mdashBrake relay (BR)1mdashPneumatic timing transition relay (TR)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Volts3Ǿ
5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current ForThese controllers have six speed points available but are used with 5point master switches the last aThese controllers have seven speed points available but are used with 6point master switches the last acceleratio
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
AC DYNAMIC LOWERINGGENERAL INFORMATION
HOIST SERVICEreversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanical
load brakes All controllers are arranged for use with rectifier operated dc shunt brakes or solenoid operated ac brakes
controller
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock for
d control circuit transformer
USES SINGLE PHASE MOTOR CONNECTION FORDYNAMIC LOWERING
SUITABLE FOR APPLICATIONS NOT REQUIRING SLOWLOWERING SPEED
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH71 DSH71 DWH715 EOH71 ESH71 EWH715 FOH71 FSH71 FWH715 GOH71 GSH71 GWH716diams GOH91 GSH91 GWH91
5 DOH71 DSH71 DWH715 EOH71 ESH71 EWH715 FOH71 FSH71 FWH715 GOH71 GSH71 GWH716diams GOH91 GSH91 GWH91
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application Dcontrollers have six speed points available but are used with 5point master switches the last acceleration point being relay controlledcontrollers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
reversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanical
USES SINGLE PHASE MOTOR CONNECTION FOR
S NOT REQUIRING SLOW
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
E SZF STATIC ACCELERATION TIMERS
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH71EAH71FAH71GAH71GAH91
DAH71EAH71FAH71GAH71GAH91
Application Datacceleration point being relay controlled
n point being relay controlled
APPLICATION INFORMATIONSee Pages 23-25DIMENSIONAL INFORMATIONSee Pages 10amp11
September 2008 FRONTLINE
DYNAMIC LOWERING ELE
FRONTLINEreg AC CRANE CONTROL
DYNAMIC LOWERING ELEMENTARY DIAGRAM
AC CRANE CONTROL
5
CLASS
MENTARY DIAGRAM
CLASS
FRONTLINE
6
CLASS
GENERAL
Class 6422 reversing CONTRA-TORQUEreg controllers are recommendedmechanical load brakes but with fixed overhauling loads such as bucket crane hoistoperated dc shunt brakes or solenoid operated ac brakes
The standard single motor reversing CONTRA-TORQUEcontroller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L)1mdashType M two-pole main contactor (M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)5 or 6mdashType SZF frequency relays
(3AR 4AR 5AR 6AR OS NH)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)2mdashPneumatic timing relays for counter-torque and lowering
relays (CTR LR)1mdashPneumatic timing transition relay (TR)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Volts5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current ForThese controllers have six speed points available but are used withdiamsThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being rel
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page
CLASS
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for use with ac wound rotor motors on crane hoistbut with fixed overhauling loads such as bucket crane hoists All controllers are arranged for use with rectifier
operated dc shunt brakes or solenoid operated ac brakes
TORQUEreg
ine circuit breaker with padlock clip
contactors with mechanical interlock for
volt fused control circuit transformer
and lowering
PROVIDES SLOW LOWERING SPEEDS FOROVERHAULING LOADS ONLY
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section ofcontrollers have six speed points available but are used with 5point master switches the last acceleration point being relay controlledcontrollers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
for use with ac wound rotor motors on crane hoists withoutarranged for use with rectifier
LOWERING SPEEDS FOR
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
STATIC ACCELERATION TIMERS
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH72EAH72FAH72GAH72GAH92
DAH72EAH72FAH72GAH72GAH92
Controller Ratings section of Application Data5point master switches the last acceleration point being relay controlled
ay controlled
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
CONTRA
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg ELEMENTARY DIAGRAM
AC CRANE CONTROL
7
CLASS
CLASS
FRONTLINE
8
CLASS
REVERSING PLUGGINGClass 6426 controllers are recommended for used withThe hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes Thereversing plugging type Both the hoist and the travel controlleroperated ac brakes
The standard single motor reversing hoist controller consists of equipment for a reversing plugging controllerfor plugging (PR)
BRIDGE OR TROLLEY SE
The standard single motor reversing controller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock1mdashType M two-pole main contactor (M)4 or 5 or 6Type M two-pole acceleration contactors (including one
for plugging) (P 1A 2A 3A 4A 5A 6A)3 or 4 or 5Type ST1 static acceleration timers
(1AR 2AR 3AR 4AR 5AR)1mdashType SZF frequency relay for plugging (PR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)
1mdashSZF power loss protection relay circuit(SPR 2RECT 2MOV 2RES)
The standard duplex reversing plugging controller consists of theequipment for a single motor controller with the exceptionfollowing equipment is added4 or 5mdashType M two-pole acceleration contactors
(2P 21A 22A 23A 24A)3mdashType AO magnetic inverse time overload relays
(4OslashL 5OslashL 6OslashL)
Volts5060Hz
CraneRating
NEMAContactor
Size
MaxAmperes
MaxHp
Primary Secondary
Primary Secondary
380
67 67 30 2 2133 133 60 3 3200 200 100 4 4400 400 150 5 5400 400 200 5 5
460
67 67 40 2 2133 133 80 3 3200 200 125 4 4400 400 200 5 5400 400 300 5 5
380
67 67 30 2 2133 133 60 3 2200 200 100 4 3400 400 150 5 4400 400 200 5 5
460
67 67 40 2 2133 67 80 3 2200 133 120 4 3400 200 200 5 4400 400 300 5 5
Select controller based on motor horsepower and rated primary and secondary current FordiamsPrice is for single motor reversing plugging or reversing hoist For reversing hoist change theThese controllers have 6 speed points available but are used with 5point master switches the last acceleration point beingThese controllers have seven speed points available but are used with 6point master swit
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING CONTROLfor used with ac wound rotor motor on hoist and travel drives of general-purpose
The hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes The travel panels are of thecontrollers are arranged for use with rectifier operated dc shunt brakes or solenoid
HOIST SERVICEThe standard single motor reversing hoist controller consists of equipment for a reversing plugging controller but without
BRIDGE OR TROLLEY SERVICE
The standard single motor reversing controller consists of
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock (F R)
including one
volt fused control circuit transformer
rsing plugging controller consists of thefor a single motor controller with the exception that the
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF FREQUENCY ACCELERATIONRELAYS FOR PLUGGING
CLASS 7001 TYPE ST1 STATICACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
DUPLEX MOTOR CONTROL5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
Select controller based on motor horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application DataPrice is for single motor reversing plugging or reversing hoist For reversing hoist change the R in the type to an H
These controllers have 6 speed points available but are used with 5point master switches the last acceleration point being relay controlledThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
purpose overhead cranespanels are of the
r operated dc shunt brakes or solenoid
out SZF frequency relay
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CLASS 8501 TYPE SZF FREQUENCY ACCELERATION
STATICACCELERATION TIMERS
DusttightEnclosure NEMA
Type 12
DAR76EAR76FAR76GAR76GAR96
DAR76EAR76FAR76GAR76GAR96
DAR86EAR86FAR86GAR86
GAR106
DAR86EAR86FAR86GAR86
GAR106Application Data
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
REVERSING PLUGGING E
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING ELEMENTARY DIAGRAM
AC CRANE CONTROL
9
CLASS
LEMENTARY DIAGRAM
CLASS
FRONTLINE
10
CLASS
CLASS
APPROXIMATE DIMENSIOSINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380VHin
mm
HOISTClasses6420 amp6422
40 3048
1219
80 6048
1219
125 10048
1219200 150
NOT A300 200
HOISTClasses6421 amp6426
ampBridge orTrolleyClass6426
40 3048
1219
80 6048
1219
125 10048
1219
NOT A200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSMOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
Win
mm
Cin
mm
NETWeightLbskg
Win
mm
Cin
mm
SINGLE MOTOR CONTROL69
175312305
52523848
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL69
175312305
50022748
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Din
mm
NETWeightLbskg
15381
750341
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
15381
700318
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
2
CLASS
GENERAL INFORMATION
Class 6420 reversing EDDYMAGreg controllers are recommended for use with ac wound rotor motors and eddy current electric load brakes oncrane hoist drives without mechanical load brakes All controllers are arranged for use with rectifier operated dc shunt braoperated ac brakes
The standard single motor reversing EDDYMAGreg controllerconsists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
LCB)2mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L)1mdashType M two-pole main contactor (M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)2 or 3mdashType ST1 static acceleration timers (3AR 4AR1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)1mdashPneumatic timing transition relay (TR)1mdashControl relay to detect loss of eddy current brake excitation
(ACDC)1mdashSet of static eddy current brake control equipment (ECBM)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashType SZF acceleration relay (5AR)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Voltage3Ǿ
5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current For These controllers have six speed points available but are used with fivediams These controllers have seven speed points available but are used with six
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONEDDYMAGreg
HOIST SERVICEcontrollers are recommended for use with ac wound rotor motors and eddy current electric load brakes on
crane hoist drives without mechanical load brakes All controllers are arranged for use with rectifier operated dc shunt bra
controller
t breaker with padlock clip
with mechanical interlock for
Type ST1 static acceleration timers (3AR 4AR 5AR)sformer
Control relay to detect loss of eddy current brake excitation
(ECBM)
PROVIDES SLOW HOISTING AND LOWERING SPEEDSFOR ALL LOADS
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 7001 TYPE ST1 STATIC ACCELERATION TIMERS REQUIRES EDDY CURRENT ELECTRIC LOAD BRAKE
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH70 DSH70 DWH705 EOH70 ESH70 EWH705 FOH70 FSH70 FWH705 GOH70 GSH70 GWH706diams GOH90 GSH90 GWH90
5 DOH70 DSH70 DWH705 EOH70 ESH70 EWH705 FOH70 FSH70 FWH705 GOH70 GSH70 GWH706diams GOH90 GSH90 GWH90
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application Dts available but are used with five speed point master switches the last acceleration point being relay controlled
but are used with six speed point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
controllers are recommended for use with ac wound rotor motors and eddy current electric load brakes oncrane hoist drives without mechanical load brakes All controllers are arranged for use with rectifier operated dc shunt brakes or solenoid
AND LOWERING SPEEDS
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
TYPE ST1 STATIC ACCELERATION TIMERSS EDDY CURRENT ELECTRIC LOAD BRAKE
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH70EAH70FAH70GAH70GAH90
DAH70EAH70FAH70GAH70GAH90
Controller Ratings section of Application Datapoint master switches the last acceleration point being relay controlled
ches the last acceleration point being relay controlled
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
EDDYMAG
FRONTLINEreg AC CRANE CONTROL
EDDYMAGreg HOIST ELEMENTARY
AC CRANE CONTROL
3
CLASS
FRONTLINE
4
CLASS
AC DYNAMIC LOWERINGGENERAL INFORMATION
Class 6421 reversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanicalload brakes All controllers are arranged for use with rectifier operated dc shunt brakes or solenoid
The standard single motor reversing dynamic loweringconsists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)4mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L DB M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)3 4 or 5mdashType SZF static acceleration relays
(2AR 3AR 4AR 5AR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)1mdashBrake relay (BR)1mdashPneumatic timing transition relay (TR)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Volts3Ǿ
5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current ForThese controllers have six speed points available but are used with 5point master switches the last aThese controllers have seven speed points available but are used with 6point master switches the last acceleratio
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
AC DYNAMIC LOWERINGGENERAL INFORMATION
HOIST SERVICEreversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanical
load brakes All controllers are arranged for use with rectifier operated dc shunt brakes or solenoid operated ac brakes
controller
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock for
d control circuit transformer
USES SINGLE PHASE MOTOR CONNECTION FORDYNAMIC LOWERING
SUITABLE FOR APPLICATIONS NOT REQUIRING SLOWLOWERING SPEED
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH71 DSH71 DWH715 EOH71 ESH71 EWH715 FOH71 FSH71 FWH715 GOH71 GSH71 GWH716diams GOH91 GSH91 GWH91
5 DOH71 DSH71 DWH715 EOH71 ESH71 EWH715 FOH71 FSH71 FWH715 GOH71 GSH71 GWH716diams GOH91 GSH91 GWH91
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application Dcontrollers have six speed points available but are used with 5point master switches the last acceleration point being relay controlledcontrollers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
reversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanical
USES SINGLE PHASE MOTOR CONNECTION FOR
S NOT REQUIRING SLOW
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
E SZF STATIC ACCELERATION TIMERS
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH71EAH71FAH71GAH71GAH91
DAH71EAH71FAH71GAH71GAH91
Application Datacceleration point being relay controlled
n point being relay controlled
APPLICATION INFORMATIONSee Pages 23-25DIMENSIONAL INFORMATIONSee Pages 10amp11
September 2008 FRONTLINE
DYNAMIC LOWERING ELE
FRONTLINEreg AC CRANE CONTROL
DYNAMIC LOWERING ELEMENTARY DIAGRAM
AC CRANE CONTROL
5
CLASS
MENTARY DIAGRAM
CLASS
FRONTLINE
6
CLASS
GENERAL
Class 6422 reversing CONTRA-TORQUEreg controllers are recommendedmechanical load brakes but with fixed overhauling loads such as bucket crane hoistoperated dc shunt brakes or solenoid operated ac brakes
The standard single motor reversing CONTRA-TORQUEcontroller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L)1mdashType M two-pole main contactor (M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)5 or 6mdashType SZF frequency relays
(3AR 4AR 5AR 6AR OS NH)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)2mdashPneumatic timing relays for counter-torque and lowering
relays (CTR LR)1mdashPneumatic timing transition relay (TR)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Volts5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current ForThese controllers have six speed points available but are used withdiamsThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being rel
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page
CLASS
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for use with ac wound rotor motors on crane hoistbut with fixed overhauling loads such as bucket crane hoists All controllers are arranged for use with rectifier
operated dc shunt brakes or solenoid operated ac brakes
TORQUEreg
ine circuit breaker with padlock clip
contactors with mechanical interlock for
volt fused control circuit transformer
and lowering
PROVIDES SLOW LOWERING SPEEDS FOROVERHAULING LOADS ONLY
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section ofcontrollers have six speed points available but are used with 5point master switches the last acceleration point being relay controlledcontrollers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
for use with ac wound rotor motors on crane hoists withoutarranged for use with rectifier
LOWERING SPEEDS FOR
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
STATIC ACCELERATION TIMERS
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH72EAH72FAH72GAH72GAH92
DAH72EAH72FAH72GAH72GAH92
Controller Ratings section of Application Data5point master switches the last acceleration point being relay controlled
ay controlled
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
CONTRA
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg ELEMENTARY DIAGRAM
AC CRANE CONTROL
7
CLASS
CLASS
FRONTLINE
8
CLASS
REVERSING PLUGGINGClass 6426 controllers are recommended for used withThe hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes Thereversing plugging type Both the hoist and the travel controlleroperated ac brakes
The standard single motor reversing hoist controller consists of equipment for a reversing plugging controllerfor plugging (PR)
BRIDGE OR TROLLEY SE
The standard single motor reversing controller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock1mdashType M two-pole main contactor (M)4 or 5 or 6Type M two-pole acceleration contactors (including one
for plugging) (P 1A 2A 3A 4A 5A 6A)3 or 4 or 5Type ST1 static acceleration timers
(1AR 2AR 3AR 4AR 5AR)1mdashType SZF frequency relay for plugging (PR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)
1mdashSZF power loss protection relay circuit(SPR 2RECT 2MOV 2RES)
The standard duplex reversing plugging controller consists of theequipment for a single motor controller with the exceptionfollowing equipment is added4 or 5mdashType M two-pole acceleration contactors
(2P 21A 22A 23A 24A)3mdashType AO magnetic inverse time overload relays
(4OslashL 5OslashL 6OslashL)
Volts5060Hz
CraneRating
NEMAContactor
Size
MaxAmperes
MaxHp
Primary Secondary
Primary Secondary
380
67 67 30 2 2133 133 60 3 3200 200 100 4 4400 400 150 5 5400 400 200 5 5
460
67 67 40 2 2133 133 80 3 3200 200 125 4 4400 400 200 5 5400 400 300 5 5
380
67 67 30 2 2133 133 60 3 2200 200 100 4 3400 400 150 5 4400 400 200 5 5
460
67 67 40 2 2133 67 80 3 2200 133 120 4 3400 200 200 5 4400 400 300 5 5
Select controller based on motor horsepower and rated primary and secondary current FordiamsPrice is for single motor reversing plugging or reversing hoist For reversing hoist change theThese controllers have 6 speed points available but are used with 5point master switches the last acceleration point beingThese controllers have seven speed points available but are used with 6point master swit
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING CONTROLfor used with ac wound rotor motor on hoist and travel drives of general-purpose
The hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes The travel panels are of thecontrollers are arranged for use with rectifier operated dc shunt brakes or solenoid
HOIST SERVICEThe standard single motor reversing hoist controller consists of equipment for a reversing plugging controller but without
BRIDGE OR TROLLEY SERVICE
The standard single motor reversing controller consists of
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock (F R)
including one
volt fused control circuit transformer
rsing plugging controller consists of thefor a single motor controller with the exception that the
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF FREQUENCY ACCELERATIONRELAYS FOR PLUGGING
CLASS 7001 TYPE ST1 STATICACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
DUPLEX MOTOR CONTROL5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
Select controller based on motor horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application DataPrice is for single motor reversing plugging or reversing hoist For reversing hoist change the R in the type to an H
These controllers have 6 speed points available but are used with 5point master switches the last acceleration point being relay controlledThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
purpose overhead cranespanels are of the
r operated dc shunt brakes or solenoid
out SZF frequency relay
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CLASS 8501 TYPE SZF FREQUENCY ACCELERATION
STATICACCELERATION TIMERS
DusttightEnclosure NEMA
Type 12
DAR76EAR76FAR76GAR76GAR96
DAR76EAR76FAR76GAR76GAR96
DAR86EAR86FAR86GAR86
GAR106
DAR86EAR86FAR86GAR86
GAR106Application Data
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
REVERSING PLUGGING E
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING ELEMENTARY DIAGRAM
AC CRANE CONTROL
9
CLASS
LEMENTARY DIAGRAM
CLASS
FRONTLINE
10
CLASS
CLASS
APPROXIMATE DIMENSIOSINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380VHin
mm
HOISTClasses6420 amp6422
40 3048
1219
80 6048
1219
125 10048
1219200 150
NOT A300 200
HOISTClasses6421 amp6426
ampBridge orTrolleyClass6426
40 3048
1219
80 6048
1219
125 10048
1219
NOT A200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSMOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
Win
mm
Cin
mm
NETWeightLbskg
Win
mm
Cin
mm
SINGLE MOTOR CONTROL69
175312305
52523848
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL69
175312305
50022748
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Din
mm
NETWeightLbskg
15381
750341
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
15381
700318
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
EDDYMAG
FRONTLINEreg AC CRANE CONTROL
EDDYMAGreg HOIST ELEMENTARY
AC CRANE CONTROL
3
CLASS
FRONTLINE
4
CLASS
AC DYNAMIC LOWERINGGENERAL INFORMATION
Class 6421 reversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanicalload brakes All controllers are arranged for use with rectifier operated dc shunt brakes or solenoid
The standard single motor reversing dynamic loweringconsists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)4mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L DB M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)3 4 or 5mdashType SZF static acceleration relays
(2AR 3AR 4AR 5AR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)1mdashBrake relay (BR)1mdashPneumatic timing transition relay (TR)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Volts3Ǿ
5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current ForThese controllers have six speed points available but are used with 5point master switches the last aThese controllers have seven speed points available but are used with 6point master switches the last acceleratio
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
AC DYNAMIC LOWERINGGENERAL INFORMATION
HOIST SERVICEreversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanical
load brakes All controllers are arranged for use with rectifier operated dc shunt brakes or solenoid operated ac brakes
controller
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock for
d control circuit transformer
USES SINGLE PHASE MOTOR CONNECTION FORDYNAMIC LOWERING
SUITABLE FOR APPLICATIONS NOT REQUIRING SLOWLOWERING SPEED
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH71 DSH71 DWH715 EOH71 ESH71 EWH715 FOH71 FSH71 FWH715 GOH71 GSH71 GWH716diams GOH91 GSH91 GWH91
5 DOH71 DSH71 DWH715 EOH71 ESH71 EWH715 FOH71 FSH71 FWH715 GOH71 GSH71 GWH716diams GOH91 GSH91 GWH91
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application Dcontrollers have six speed points available but are used with 5point master switches the last acceleration point being relay controlledcontrollers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
reversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanical
USES SINGLE PHASE MOTOR CONNECTION FOR
S NOT REQUIRING SLOW
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
E SZF STATIC ACCELERATION TIMERS
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH71EAH71FAH71GAH71GAH91
DAH71EAH71FAH71GAH71GAH91
Application Datacceleration point being relay controlled
n point being relay controlled
APPLICATION INFORMATIONSee Pages 23-25DIMENSIONAL INFORMATIONSee Pages 10amp11
September 2008 FRONTLINE
DYNAMIC LOWERING ELE
FRONTLINEreg AC CRANE CONTROL
DYNAMIC LOWERING ELEMENTARY DIAGRAM
AC CRANE CONTROL
5
CLASS
MENTARY DIAGRAM
CLASS
FRONTLINE
6
CLASS
GENERAL
Class 6422 reversing CONTRA-TORQUEreg controllers are recommendedmechanical load brakes but with fixed overhauling loads such as bucket crane hoistoperated dc shunt brakes or solenoid operated ac brakes
The standard single motor reversing CONTRA-TORQUEcontroller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L)1mdashType M two-pole main contactor (M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)5 or 6mdashType SZF frequency relays
(3AR 4AR 5AR 6AR OS NH)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)2mdashPneumatic timing relays for counter-torque and lowering
relays (CTR LR)1mdashPneumatic timing transition relay (TR)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Volts5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current ForThese controllers have six speed points available but are used withdiamsThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being rel
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page
CLASS
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for use with ac wound rotor motors on crane hoistbut with fixed overhauling loads such as bucket crane hoists All controllers are arranged for use with rectifier
operated dc shunt brakes or solenoid operated ac brakes
TORQUEreg
ine circuit breaker with padlock clip
contactors with mechanical interlock for
volt fused control circuit transformer
and lowering
PROVIDES SLOW LOWERING SPEEDS FOROVERHAULING LOADS ONLY
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section ofcontrollers have six speed points available but are used with 5point master switches the last acceleration point being relay controlledcontrollers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
for use with ac wound rotor motors on crane hoists withoutarranged for use with rectifier
LOWERING SPEEDS FOR
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
STATIC ACCELERATION TIMERS
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH72EAH72FAH72GAH72GAH92
DAH72EAH72FAH72GAH72GAH92
Controller Ratings section of Application Data5point master switches the last acceleration point being relay controlled
ay controlled
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
CONTRA
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg ELEMENTARY DIAGRAM
AC CRANE CONTROL
7
CLASS
CLASS
FRONTLINE
8
CLASS
REVERSING PLUGGINGClass 6426 controllers are recommended for used withThe hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes Thereversing plugging type Both the hoist and the travel controlleroperated ac brakes
The standard single motor reversing hoist controller consists of equipment for a reversing plugging controllerfor plugging (PR)
BRIDGE OR TROLLEY SE
The standard single motor reversing controller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock1mdashType M two-pole main contactor (M)4 or 5 or 6Type M two-pole acceleration contactors (including one
for plugging) (P 1A 2A 3A 4A 5A 6A)3 or 4 or 5Type ST1 static acceleration timers
(1AR 2AR 3AR 4AR 5AR)1mdashType SZF frequency relay for plugging (PR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)
1mdashSZF power loss protection relay circuit(SPR 2RECT 2MOV 2RES)
The standard duplex reversing plugging controller consists of theequipment for a single motor controller with the exceptionfollowing equipment is added4 or 5mdashType M two-pole acceleration contactors
(2P 21A 22A 23A 24A)3mdashType AO magnetic inverse time overload relays
(4OslashL 5OslashL 6OslashL)
Volts5060Hz
CraneRating
NEMAContactor
Size
MaxAmperes
MaxHp
Primary Secondary
Primary Secondary
380
67 67 30 2 2133 133 60 3 3200 200 100 4 4400 400 150 5 5400 400 200 5 5
460
67 67 40 2 2133 133 80 3 3200 200 125 4 4400 400 200 5 5400 400 300 5 5
380
67 67 30 2 2133 133 60 3 2200 200 100 4 3400 400 150 5 4400 400 200 5 5
460
67 67 40 2 2133 67 80 3 2200 133 120 4 3400 200 200 5 4400 400 300 5 5
Select controller based on motor horsepower and rated primary and secondary current FordiamsPrice is for single motor reversing plugging or reversing hoist For reversing hoist change theThese controllers have 6 speed points available but are used with 5point master switches the last acceleration point beingThese controllers have seven speed points available but are used with 6point master swit
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING CONTROLfor used with ac wound rotor motor on hoist and travel drives of general-purpose
The hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes The travel panels are of thecontrollers are arranged for use with rectifier operated dc shunt brakes or solenoid
HOIST SERVICEThe standard single motor reversing hoist controller consists of equipment for a reversing plugging controller but without
BRIDGE OR TROLLEY SERVICE
The standard single motor reversing controller consists of
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock (F R)
including one
volt fused control circuit transformer
rsing plugging controller consists of thefor a single motor controller with the exception that the
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF FREQUENCY ACCELERATIONRELAYS FOR PLUGGING
CLASS 7001 TYPE ST1 STATICACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
DUPLEX MOTOR CONTROL5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
Select controller based on motor horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application DataPrice is for single motor reversing plugging or reversing hoist For reversing hoist change the R in the type to an H
These controllers have 6 speed points available but are used with 5point master switches the last acceleration point being relay controlledThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
purpose overhead cranespanels are of the
r operated dc shunt brakes or solenoid
out SZF frequency relay
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CLASS 8501 TYPE SZF FREQUENCY ACCELERATION
STATICACCELERATION TIMERS
DusttightEnclosure NEMA
Type 12
DAR76EAR76FAR76GAR76GAR96
DAR76EAR76FAR76GAR76GAR96
DAR86EAR86FAR86GAR86
GAR106
DAR86EAR86FAR86GAR86
GAR106Application Data
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
REVERSING PLUGGING E
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING ELEMENTARY DIAGRAM
AC CRANE CONTROL
9
CLASS
LEMENTARY DIAGRAM
CLASS
FRONTLINE
10
CLASS
CLASS
APPROXIMATE DIMENSIOSINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380VHin
mm
HOISTClasses6420 amp6422
40 3048
1219
80 6048
1219
125 10048
1219200 150
NOT A300 200
HOISTClasses6421 amp6426
ampBridge orTrolleyClass6426
40 3048
1219
80 6048
1219
125 10048
1219
NOT A200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSMOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
Win
mm
Cin
mm
NETWeightLbskg
Win
mm
Cin
mm
SINGLE MOTOR CONTROL69
175312305
52523848
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL69
175312305
50022748
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Din
mm
NETWeightLbskg
15381
750341
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
15381
700318
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
4
CLASS
AC DYNAMIC LOWERINGGENERAL INFORMATION
Class 6421 reversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanicalload brakes All controllers are arranged for use with rectifier operated dc shunt brakes or solenoid
The standard single motor reversing dynamic loweringconsists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)4mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L DB M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)3 4 or 5mdashType SZF static acceleration relays
(2AR 3AR 4AR 5AR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)1mdashBrake relay (BR)1mdashPneumatic timing transition relay (TR)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Volts3Ǿ
5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current ForThese controllers have six speed points available but are used with 5point master switches the last aThese controllers have seven speed points available but are used with 6point master switches the last acceleratio
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
AC DYNAMIC LOWERINGGENERAL INFORMATION
HOIST SERVICEreversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanical
load brakes All controllers are arranged for use with rectifier operated dc shunt brakes or solenoid operated ac brakes
controller
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock for
d control circuit transformer
USES SINGLE PHASE MOTOR CONNECTION FORDYNAMIC LOWERING
SUITABLE FOR APPLICATIONS NOT REQUIRING SLOWLOWERING SPEED
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH71 DSH71 DWH715 EOH71 ESH71 EWH715 FOH71 FSH71 FWH715 GOH71 GSH71 GWH716diams GOH91 GSH91 GWH91
5 DOH71 DSH71 DWH715 EOH71 ESH71 EWH715 FOH71 FSH71 FWH715 GOH71 GSH71 GWH716diams GOH91 GSH91 GWH91
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application Dcontrollers have six speed points available but are used with 5point master switches the last acceleration point being relay controlledcontrollers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
reversing dynamic lowering controllers are recommended for use with ac wound rotor motors on crane hoist without mechanical
USES SINGLE PHASE MOTOR CONNECTION FOR
S NOT REQUIRING SLOW
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
E SZF STATIC ACCELERATION TIMERS
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH71EAH71FAH71GAH71GAH91
DAH71EAH71FAH71GAH71GAH91
Application Datacceleration point being relay controlled
n point being relay controlled
APPLICATION INFORMATIONSee Pages 23-25DIMENSIONAL INFORMATIONSee Pages 10amp11
September 2008 FRONTLINE
DYNAMIC LOWERING ELE
FRONTLINEreg AC CRANE CONTROL
DYNAMIC LOWERING ELEMENTARY DIAGRAM
AC CRANE CONTROL
5
CLASS
MENTARY DIAGRAM
CLASS
FRONTLINE
6
CLASS
GENERAL
Class 6422 reversing CONTRA-TORQUEreg controllers are recommendedmechanical load brakes but with fixed overhauling loads such as bucket crane hoistoperated dc shunt brakes or solenoid operated ac brakes
The standard single motor reversing CONTRA-TORQUEcontroller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L)1mdashType M two-pole main contactor (M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)5 or 6mdashType SZF frequency relays
(3AR 4AR 5AR 6AR OS NH)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)2mdashPneumatic timing relays for counter-torque and lowering
relays (CTR LR)1mdashPneumatic timing transition relay (TR)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Volts5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current ForThese controllers have six speed points available but are used withdiamsThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being rel
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page
CLASS
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for use with ac wound rotor motors on crane hoistbut with fixed overhauling loads such as bucket crane hoists All controllers are arranged for use with rectifier
operated dc shunt brakes or solenoid operated ac brakes
TORQUEreg
ine circuit breaker with padlock clip
contactors with mechanical interlock for
volt fused control circuit transformer
and lowering
PROVIDES SLOW LOWERING SPEEDS FOROVERHAULING LOADS ONLY
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section ofcontrollers have six speed points available but are used with 5point master switches the last acceleration point being relay controlledcontrollers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
for use with ac wound rotor motors on crane hoists withoutarranged for use with rectifier
LOWERING SPEEDS FOR
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
STATIC ACCELERATION TIMERS
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH72EAH72FAH72GAH72GAH92
DAH72EAH72FAH72GAH72GAH92
Controller Ratings section of Application Data5point master switches the last acceleration point being relay controlled
ay controlled
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
CONTRA
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg ELEMENTARY DIAGRAM
AC CRANE CONTROL
7
CLASS
CLASS
FRONTLINE
8
CLASS
REVERSING PLUGGINGClass 6426 controllers are recommended for used withThe hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes Thereversing plugging type Both the hoist and the travel controlleroperated ac brakes
The standard single motor reversing hoist controller consists of equipment for a reversing plugging controllerfor plugging (PR)
BRIDGE OR TROLLEY SE
The standard single motor reversing controller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock1mdashType M two-pole main contactor (M)4 or 5 or 6Type M two-pole acceleration contactors (including one
for plugging) (P 1A 2A 3A 4A 5A 6A)3 or 4 or 5Type ST1 static acceleration timers
(1AR 2AR 3AR 4AR 5AR)1mdashType SZF frequency relay for plugging (PR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)
1mdashSZF power loss protection relay circuit(SPR 2RECT 2MOV 2RES)
The standard duplex reversing plugging controller consists of theequipment for a single motor controller with the exceptionfollowing equipment is added4 or 5mdashType M two-pole acceleration contactors
(2P 21A 22A 23A 24A)3mdashType AO magnetic inverse time overload relays
(4OslashL 5OslashL 6OslashL)
Volts5060Hz
CraneRating
NEMAContactor
Size
MaxAmperes
MaxHp
Primary Secondary
Primary Secondary
380
67 67 30 2 2133 133 60 3 3200 200 100 4 4400 400 150 5 5400 400 200 5 5
460
67 67 40 2 2133 133 80 3 3200 200 125 4 4400 400 200 5 5400 400 300 5 5
380
67 67 30 2 2133 133 60 3 2200 200 100 4 3400 400 150 5 4400 400 200 5 5
460
67 67 40 2 2133 67 80 3 2200 133 120 4 3400 200 200 5 4400 400 300 5 5
Select controller based on motor horsepower and rated primary and secondary current FordiamsPrice is for single motor reversing plugging or reversing hoist For reversing hoist change theThese controllers have 6 speed points available but are used with 5point master switches the last acceleration point beingThese controllers have seven speed points available but are used with 6point master swit
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING CONTROLfor used with ac wound rotor motor on hoist and travel drives of general-purpose
The hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes The travel panels are of thecontrollers are arranged for use with rectifier operated dc shunt brakes or solenoid
HOIST SERVICEThe standard single motor reversing hoist controller consists of equipment for a reversing plugging controller but without
BRIDGE OR TROLLEY SERVICE
The standard single motor reversing controller consists of
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock (F R)
including one
volt fused control circuit transformer
rsing plugging controller consists of thefor a single motor controller with the exception that the
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF FREQUENCY ACCELERATIONRELAYS FOR PLUGGING
CLASS 7001 TYPE ST1 STATICACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
DUPLEX MOTOR CONTROL5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
Select controller based on motor horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application DataPrice is for single motor reversing plugging or reversing hoist For reversing hoist change the R in the type to an H
These controllers have 6 speed points available but are used with 5point master switches the last acceleration point being relay controlledThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
purpose overhead cranespanels are of the
r operated dc shunt brakes or solenoid
out SZF frequency relay
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CLASS 8501 TYPE SZF FREQUENCY ACCELERATION
STATICACCELERATION TIMERS
DusttightEnclosure NEMA
Type 12
DAR76EAR76FAR76GAR76GAR96
DAR76EAR76FAR76GAR76GAR96
DAR86EAR86FAR86GAR86
GAR106
DAR86EAR86FAR86GAR86
GAR106Application Data
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
REVERSING PLUGGING E
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING ELEMENTARY DIAGRAM
AC CRANE CONTROL
9
CLASS
LEMENTARY DIAGRAM
CLASS
FRONTLINE
10
CLASS
CLASS
APPROXIMATE DIMENSIOSINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380VHin
mm
HOISTClasses6420 amp6422
40 3048
1219
80 6048
1219
125 10048
1219200 150
NOT A300 200
HOISTClasses6421 amp6426
ampBridge orTrolleyClass6426
40 3048
1219
80 6048
1219
125 10048
1219
NOT A200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSMOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
Win
mm
Cin
mm
NETWeightLbskg
Win
mm
Cin
mm
SINGLE MOTOR CONTROL69
175312305
52523848
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL69
175312305
50022748
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Din
mm
NETWeightLbskg
15381
750341
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
15381
700318
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
DYNAMIC LOWERING ELE
FRONTLINEreg AC CRANE CONTROL
DYNAMIC LOWERING ELEMENTARY DIAGRAM
AC CRANE CONTROL
5
CLASS
MENTARY DIAGRAM
CLASS
FRONTLINE
6
CLASS
GENERAL
Class 6422 reversing CONTRA-TORQUEreg controllers are recommendedmechanical load brakes but with fixed overhauling loads such as bucket crane hoistoperated dc shunt brakes or solenoid operated ac brakes
The standard single motor reversing CONTRA-TORQUEcontroller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L)1mdashType M two-pole main contactor (M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)5 or 6mdashType SZF frequency relays
(3AR 4AR 5AR 6AR OS NH)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)2mdashPneumatic timing relays for counter-torque and lowering
relays (CTR LR)1mdashPneumatic timing transition relay (TR)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Volts5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current ForThese controllers have six speed points available but are used withdiamsThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being rel
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page
CLASS
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for use with ac wound rotor motors on crane hoistbut with fixed overhauling loads such as bucket crane hoists All controllers are arranged for use with rectifier
operated dc shunt brakes or solenoid operated ac brakes
TORQUEreg
ine circuit breaker with padlock clip
contactors with mechanical interlock for
volt fused control circuit transformer
and lowering
PROVIDES SLOW LOWERING SPEEDS FOROVERHAULING LOADS ONLY
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section ofcontrollers have six speed points available but are used with 5point master switches the last acceleration point being relay controlledcontrollers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
for use with ac wound rotor motors on crane hoists withoutarranged for use with rectifier
LOWERING SPEEDS FOR
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
STATIC ACCELERATION TIMERS
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH72EAH72FAH72GAH72GAH92
DAH72EAH72FAH72GAH72GAH92
Controller Ratings section of Application Data5point master switches the last acceleration point being relay controlled
ay controlled
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
CONTRA
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg ELEMENTARY DIAGRAM
AC CRANE CONTROL
7
CLASS
CLASS
FRONTLINE
8
CLASS
REVERSING PLUGGINGClass 6426 controllers are recommended for used withThe hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes Thereversing plugging type Both the hoist and the travel controlleroperated ac brakes
The standard single motor reversing hoist controller consists of equipment for a reversing plugging controllerfor plugging (PR)
BRIDGE OR TROLLEY SE
The standard single motor reversing controller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock1mdashType M two-pole main contactor (M)4 or 5 or 6Type M two-pole acceleration contactors (including one
for plugging) (P 1A 2A 3A 4A 5A 6A)3 or 4 or 5Type ST1 static acceleration timers
(1AR 2AR 3AR 4AR 5AR)1mdashType SZF frequency relay for plugging (PR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)
1mdashSZF power loss protection relay circuit(SPR 2RECT 2MOV 2RES)
The standard duplex reversing plugging controller consists of theequipment for a single motor controller with the exceptionfollowing equipment is added4 or 5mdashType M two-pole acceleration contactors
(2P 21A 22A 23A 24A)3mdashType AO magnetic inverse time overload relays
(4OslashL 5OslashL 6OslashL)
Volts5060Hz
CraneRating
NEMAContactor
Size
MaxAmperes
MaxHp
Primary Secondary
Primary Secondary
380
67 67 30 2 2133 133 60 3 3200 200 100 4 4400 400 150 5 5400 400 200 5 5
460
67 67 40 2 2133 133 80 3 3200 200 125 4 4400 400 200 5 5400 400 300 5 5
380
67 67 30 2 2133 133 60 3 2200 200 100 4 3400 400 150 5 4400 400 200 5 5
460
67 67 40 2 2133 67 80 3 2200 133 120 4 3400 200 200 5 4400 400 300 5 5
Select controller based on motor horsepower and rated primary and secondary current FordiamsPrice is for single motor reversing plugging or reversing hoist For reversing hoist change theThese controllers have 6 speed points available but are used with 5point master switches the last acceleration point beingThese controllers have seven speed points available but are used with 6point master swit
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING CONTROLfor used with ac wound rotor motor on hoist and travel drives of general-purpose
The hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes The travel panels are of thecontrollers are arranged for use with rectifier operated dc shunt brakes or solenoid
HOIST SERVICEThe standard single motor reversing hoist controller consists of equipment for a reversing plugging controller but without
BRIDGE OR TROLLEY SERVICE
The standard single motor reversing controller consists of
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock (F R)
including one
volt fused control circuit transformer
rsing plugging controller consists of thefor a single motor controller with the exception that the
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF FREQUENCY ACCELERATIONRELAYS FOR PLUGGING
CLASS 7001 TYPE ST1 STATICACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
DUPLEX MOTOR CONTROL5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
Select controller based on motor horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application DataPrice is for single motor reversing plugging or reversing hoist For reversing hoist change the R in the type to an H
These controllers have 6 speed points available but are used with 5point master switches the last acceleration point being relay controlledThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
purpose overhead cranespanels are of the
r operated dc shunt brakes or solenoid
out SZF frequency relay
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CLASS 8501 TYPE SZF FREQUENCY ACCELERATION
STATICACCELERATION TIMERS
DusttightEnclosure NEMA
Type 12
DAR76EAR76FAR76GAR76GAR96
DAR76EAR76FAR76GAR76GAR96
DAR86EAR86FAR86GAR86
GAR106
DAR86EAR86FAR86GAR86
GAR106Application Data
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
REVERSING PLUGGING E
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING ELEMENTARY DIAGRAM
AC CRANE CONTROL
9
CLASS
LEMENTARY DIAGRAM
CLASS
FRONTLINE
10
CLASS
CLASS
APPROXIMATE DIMENSIOSINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380VHin
mm
HOISTClasses6420 amp6422
40 3048
1219
80 6048
1219
125 10048
1219200 150
NOT A300 200
HOISTClasses6421 amp6426
ampBridge orTrolleyClass6426
40 3048
1219
80 6048
1219
125 10048
1219
NOT A200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSMOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
Win
mm
Cin
mm
NETWeightLbskg
Win
mm
Cin
mm
SINGLE MOTOR CONTROL69
175312305
52523848
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL69
175312305
50022748
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Din
mm
NETWeightLbskg
15381
750341
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
15381
700318
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
6
CLASS
GENERAL
Class 6422 reversing CONTRA-TORQUEreg controllers are recommendedmechanical load brakes but with fixed overhauling loads such as bucket crane hoistoperated dc shunt brakes or solenoid operated ac brakes
The standard single motor reversing CONTRA-TORQUEcontroller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H L)1mdashType M two-pole main contactor (M)5 or 6mdashType M two-pole acceleration contactors
(1A 2A 3A 4A 5A 6A)5 or 6mdashType SZF frequency relays
(3AR 4AR 5AR 6AR OS NH)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)2mdashPneumatic timing relays for counter-torque and lowering
relays (CTR LR)1mdashPneumatic timing transition relay (TR)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)1mdashSZF power loss protection relay circuits
(SPR 2RECT 2MOV 2RES)
Volts5060Hz
CraneRating
NEMAContactor
SizeMax
AmperesMaxHp
Primary Secondary
380
67 30 2 2133 60 3 3200 100 4 4400 150 5 5400 200 5 5
460
67 40 2 2133 80 3 3200 125 4 4400 200 5 5400 300 5 5
Select controller based on horsepower and rated primary and secondary current ForThese controllers have six speed points available but are used withdiamsThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being rel
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page
CLASS
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for use with ac wound rotor motors on crane hoistbut with fixed overhauling loads such as bucket crane hoists All controllers are arranged for use with rectifier
operated dc shunt brakes or solenoid operated ac brakes
TORQUEreg
ine circuit breaker with padlock clip
contactors with mechanical interlock for
volt fused control circuit transformer
and lowering
PROVIDES SLOW LOWERING SPEEDS FOROVERHAULING LOADS ONLY
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
5 DOH72 DSH72 DWH725 EOH72 ESH72 EWH725 FOH72 FSH72 FWH725 GOH72 GSH72 GWH726diams GOH92 GSH92 GWH92
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section ofcontrollers have six speed points available but are used with 5point master switches the last acceleration point being relay controlledcontrollers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
for use with ac wound rotor motors on crane hoists withoutarranged for use with rectifier
LOWERING SPEEDS FOR
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
STATIC ACCELERATION TIMERS
Outdoor EnclosureDusttight
Enclosure NEMAType 12
DAH72EAH72FAH72GAH72GAH92
DAH72EAH72FAH72GAH72GAH92
Controller Ratings section of Application Data5point master switches the last acceleration point being relay controlled
ay controlled
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
CONTRA
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg ELEMENTARY DIAGRAM
AC CRANE CONTROL
7
CLASS
CLASS
FRONTLINE
8
CLASS
REVERSING PLUGGINGClass 6426 controllers are recommended for used withThe hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes Thereversing plugging type Both the hoist and the travel controlleroperated ac brakes
The standard single motor reversing hoist controller consists of equipment for a reversing plugging controllerfor plugging (PR)
BRIDGE OR TROLLEY SE
The standard single motor reversing controller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock1mdashType M two-pole main contactor (M)4 or 5 or 6Type M two-pole acceleration contactors (including one
for plugging) (P 1A 2A 3A 4A 5A 6A)3 or 4 or 5Type ST1 static acceleration timers
(1AR 2AR 3AR 4AR 5AR)1mdashType SZF frequency relay for plugging (PR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)
1mdashSZF power loss protection relay circuit(SPR 2RECT 2MOV 2RES)
The standard duplex reversing plugging controller consists of theequipment for a single motor controller with the exceptionfollowing equipment is added4 or 5mdashType M two-pole acceleration contactors
(2P 21A 22A 23A 24A)3mdashType AO magnetic inverse time overload relays
(4OslashL 5OslashL 6OslashL)
Volts5060Hz
CraneRating
NEMAContactor
Size
MaxAmperes
MaxHp
Primary Secondary
Primary Secondary
380
67 67 30 2 2133 133 60 3 3200 200 100 4 4400 400 150 5 5400 400 200 5 5
460
67 67 40 2 2133 133 80 3 3200 200 125 4 4400 400 200 5 5400 400 300 5 5
380
67 67 30 2 2133 133 60 3 2200 200 100 4 3400 400 150 5 4400 400 200 5 5
460
67 67 40 2 2133 67 80 3 2200 133 120 4 3400 200 200 5 4400 400 300 5 5
Select controller based on motor horsepower and rated primary and secondary current FordiamsPrice is for single motor reversing plugging or reversing hoist For reversing hoist change theThese controllers have 6 speed points available but are used with 5point master switches the last acceleration point beingThese controllers have seven speed points available but are used with 6point master swit
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING CONTROLfor used with ac wound rotor motor on hoist and travel drives of general-purpose
The hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes The travel panels are of thecontrollers are arranged for use with rectifier operated dc shunt brakes or solenoid
HOIST SERVICEThe standard single motor reversing hoist controller consists of equipment for a reversing plugging controller but without
BRIDGE OR TROLLEY SERVICE
The standard single motor reversing controller consists of
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock (F R)
including one
volt fused control circuit transformer
rsing plugging controller consists of thefor a single motor controller with the exception that the
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF FREQUENCY ACCELERATIONRELAYS FOR PLUGGING
CLASS 7001 TYPE ST1 STATICACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
DUPLEX MOTOR CONTROL5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
Select controller based on motor horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application DataPrice is for single motor reversing plugging or reversing hoist For reversing hoist change the R in the type to an H
These controllers have 6 speed points available but are used with 5point master switches the last acceleration point being relay controlledThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
purpose overhead cranespanels are of the
r operated dc shunt brakes or solenoid
out SZF frequency relay
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CLASS 8501 TYPE SZF FREQUENCY ACCELERATION
STATICACCELERATION TIMERS
DusttightEnclosure NEMA
Type 12
DAR76EAR76FAR76GAR76GAR96
DAR76EAR76FAR76GAR76GAR96
DAR86EAR86FAR86GAR86
GAR106
DAR86EAR86FAR86GAR86
GAR106Application Data
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
REVERSING PLUGGING E
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING ELEMENTARY DIAGRAM
AC CRANE CONTROL
9
CLASS
LEMENTARY DIAGRAM
CLASS
FRONTLINE
10
CLASS
CLASS
APPROXIMATE DIMENSIOSINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380VHin
mm
HOISTClasses6420 amp6422
40 3048
1219
80 6048
1219
125 10048
1219200 150
NOT A300 200
HOISTClasses6421 amp6426
ampBridge orTrolleyClass6426
40 3048
1219
80 6048
1219
125 10048
1219
NOT A200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSMOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
Win
mm
Cin
mm
NETWeightLbskg
Win
mm
Cin
mm
SINGLE MOTOR CONTROL69
175312305
52523848
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL69
175312305
50022748
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Din
mm
NETWeightLbskg
15381
750341
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
15381
700318
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
CONTRA
FRONTLINEreg AC CRANE CONTROL
CONTRA-TORQUEreg ELEMENTARY DIAGRAM
AC CRANE CONTROL
7
CLASS
CLASS
FRONTLINE
8
CLASS
REVERSING PLUGGINGClass 6426 controllers are recommended for used withThe hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes Thereversing plugging type Both the hoist and the travel controlleroperated ac brakes
The standard single motor reversing hoist controller consists of equipment for a reversing plugging controllerfor plugging (PR)
BRIDGE OR TROLLEY SE
The standard single motor reversing controller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock1mdashType M two-pole main contactor (M)4 or 5 or 6Type M two-pole acceleration contactors (including one
for plugging) (P 1A 2A 3A 4A 5A 6A)3 or 4 or 5Type ST1 static acceleration timers
(1AR 2AR 3AR 4AR 5AR)1mdashType SZF frequency relay for plugging (PR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)
1mdashSZF power loss protection relay circuit(SPR 2RECT 2MOV 2RES)
The standard duplex reversing plugging controller consists of theequipment for a single motor controller with the exceptionfollowing equipment is added4 or 5mdashType M two-pole acceleration contactors
(2P 21A 22A 23A 24A)3mdashType AO magnetic inverse time overload relays
(4OslashL 5OslashL 6OslashL)
Volts5060Hz
CraneRating
NEMAContactor
Size
MaxAmperes
MaxHp
Primary Secondary
Primary Secondary
380
67 67 30 2 2133 133 60 3 3200 200 100 4 4400 400 150 5 5400 400 200 5 5
460
67 67 40 2 2133 133 80 3 3200 200 125 4 4400 400 200 5 5400 400 300 5 5
380
67 67 30 2 2133 133 60 3 2200 200 100 4 3400 400 150 5 4400 400 200 5 5
460
67 67 40 2 2133 67 80 3 2200 133 120 4 3400 200 200 5 4400 400 300 5 5
Select controller based on motor horsepower and rated primary and secondary current FordiamsPrice is for single motor reversing plugging or reversing hoist For reversing hoist change theThese controllers have 6 speed points available but are used with 5point master switches the last acceleration point beingThese controllers have seven speed points available but are used with 6point master swit
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING CONTROLfor used with ac wound rotor motor on hoist and travel drives of general-purpose
The hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes The travel panels are of thecontrollers are arranged for use with rectifier operated dc shunt brakes or solenoid
HOIST SERVICEThe standard single motor reversing hoist controller consists of equipment for a reversing plugging controller but without
BRIDGE OR TROLLEY SERVICE
The standard single motor reversing controller consists of
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock (F R)
including one
volt fused control circuit transformer
rsing plugging controller consists of thefor a single motor controller with the exception that the
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF FREQUENCY ACCELERATIONRELAYS FOR PLUGGING
CLASS 7001 TYPE ST1 STATICACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
DUPLEX MOTOR CONTROL5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
Select controller based on motor horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application DataPrice is for single motor reversing plugging or reversing hoist For reversing hoist change the R in the type to an H
These controllers have 6 speed points available but are used with 5point master switches the last acceleration point being relay controlledThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
purpose overhead cranespanels are of the
r operated dc shunt brakes or solenoid
out SZF frequency relay
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CLASS 8501 TYPE SZF FREQUENCY ACCELERATION
STATICACCELERATION TIMERS
DusttightEnclosure NEMA
Type 12
DAR76EAR76FAR76GAR76GAR96
DAR76EAR76FAR76GAR76GAR96
DAR86EAR86FAR86GAR86
GAR106
DAR86EAR86FAR86GAR86
GAR106Application Data
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
REVERSING PLUGGING E
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING ELEMENTARY DIAGRAM
AC CRANE CONTROL
9
CLASS
LEMENTARY DIAGRAM
CLASS
FRONTLINE
10
CLASS
CLASS
APPROXIMATE DIMENSIOSINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380VHin
mm
HOISTClasses6420 amp6422
40 3048
1219
80 6048
1219
125 10048
1219200 150
NOT A300 200
HOISTClasses6421 amp6426
ampBridge orTrolleyClass6426
40 3048
1219
80 6048
1219
125 10048
1219
NOT A200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSMOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
Win
mm
Cin
mm
NETWeightLbskg
Win
mm
Cin
mm
SINGLE MOTOR CONTROL69
175312305
52523848
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL69
175312305
50022748
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Din
mm
NETWeightLbskg
15381
750341
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
15381
700318
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
8
CLASS
REVERSING PLUGGINGClass 6426 controllers are recommended for used withThe hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes Thereversing plugging type Both the hoist and the travel controlleroperated ac brakes
The standard single motor reversing hoist controller consists of equipment for a reversing plugging controllerfor plugging (PR)
BRIDGE OR TROLLEY SE
The standard single motor reversing controller consists of
1mdashTwo pole control molded case switch (CMCS)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType M two-pole contactors with mechanical interlock1mdashType M two-pole main contactor (M)4 or 5 or 6Type M two-pole acceleration contactors (including one
for plugging) (P 1A 2A 3A 4A 5A 6A)3 or 4 or 5Type ST1 static acceleration timers
(1AR 2AR 3AR 4AR 5AR)1mdashType SZF frequency relay for plugging (PR)1mdash460380230 to 255 volt fused control circuit transformer
(CTR)1mdashControl Circuit Rectifier (RECT)1mdashType KFO under voltage relay (UV)3mdashType AO magnetic inverse time overload relays
(1OslashL 2OslashL 3OslashL)
1mdashSZF power loss protection relay circuit(SPR 2RECT 2MOV 2RES)
The standard duplex reversing plugging controller consists of theequipment for a single motor controller with the exceptionfollowing equipment is added4 or 5mdashType M two-pole acceleration contactors
(2P 21A 22A 23A 24A)3mdashType AO magnetic inverse time overload relays
(4OslashL 5OslashL 6OslashL)
Volts5060Hz
CraneRating
NEMAContactor
Size
MaxAmperes
MaxHp
Primary Secondary
Primary Secondary
380
67 67 30 2 2133 133 60 3 3200 200 100 4 4400 400 150 5 5400 400 200 5 5
460
67 67 40 2 2133 133 80 3 3200 200 125 4 4400 400 200 5 5400 400 300 5 5
380
67 67 30 2 2133 133 60 3 2200 200 100 4 3400 400 150 5 4400 400 200 5 5
460
67 67 40 2 2133 67 80 3 2200 133 120 4 3400 200 200 5 4400 400 300 5 5
Select controller based on motor horsepower and rated primary and secondary current FordiamsPrice is for single motor reversing plugging or reversing hoist For reversing hoist change theThese controllers have 6 speed points available but are used with 5point master switches the last acceleration point beingThese controllers have seven speed points available but are used with 6point master swit
ORDERING INFORMATION REQUIRED See Page 23MODIFICATIONS See Page 24
CLASS
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING CONTROLfor used with ac wound rotor motor on hoist and travel drives of general-purpose
The hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes The travel panels are of thecontrollers are arranged for use with rectifier operated dc shunt brakes or solenoid
HOIST SERVICEThe standard single motor reversing hoist controller consists of equipment for a reversing plugging controller but without
BRIDGE OR TROLLEY SERVICE
The standard single motor reversing controller consists of
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical interlock (F R)
including one
volt fused control circuit transformer
rsing plugging controller consists of thefor a single motor controller with the exception that the
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPECONTACTORS
CLASS 8501 TYPE SZF FREQUENCY ACCELERATIONRELAYS FOR PLUGGING
CLASS 7001 TYPE ST1 STATICACCELERATION TIMERS
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
Outdoor EnclosureNEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
5 DOR76 DSR76 DWR765 EOR76 ESR76 EWR765 FOR76 FSR76 FWR765 GOR76 GSR76 GWR766 GOR96 GSR96 GWR96
DUPLEX MOTOR CONTROL5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
5 DOR86 DSR86 DWR865 EOR86 ESR86 EWR865 FOR86 FSR86 FWR865 GOR86 GSR86 GWR865 GOR106 GSR106 GWR106
Select controller based on motor horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of Application DataPrice is for single motor reversing plugging or reversing hoist For reversing hoist change the R in the type to an H
These controllers have 6 speed points available but are used with 5point master switches the last acceleration point being relay controlledThese controllers have seven speed points available but are used with 6point master switches the last acceleration point being relay controlled
See Page 23See Page 24
APPLICATION INFORMATIONDIMENSIONAL INFORMATION
September 2008
purpose overhead cranespanels are of the
r operated dc shunt brakes or solenoid
out SZF frequency relay
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CLASS 8501 TYPE SZF FREQUENCY ACCELERATION
STATICACCELERATION TIMERS
DusttightEnclosure NEMA
Type 12
DAR76EAR76FAR76GAR76GAR96
DAR76EAR76FAR76GAR76GAR96
DAR86EAR86FAR86GAR86
GAR106
DAR86EAR86FAR86GAR86
GAR106Application Data
APPLICATION INFORMATION See Pages 23-25DIMENSIONAL INFORMATION See Pages 10amp11
September 2008 FRONTLINE
REVERSING PLUGGING E
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING ELEMENTARY DIAGRAM
AC CRANE CONTROL
9
CLASS
LEMENTARY DIAGRAM
CLASS
FRONTLINE
10
CLASS
CLASS
APPROXIMATE DIMENSIOSINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380VHin
mm
HOISTClasses6420 amp6422
40 3048
1219
80 6048
1219
125 10048
1219200 150
NOT A300 200
HOISTClasses6421 amp6426
ampBridge orTrolleyClass6426
40 3048
1219
80 6048
1219
125 10048
1219
NOT A200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSMOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
Win
mm
Cin
mm
NETWeightLbskg
Win
mm
Cin
mm
SINGLE MOTOR CONTROL69
175312305
52523848
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL69
175312305
50022748
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Din
mm
NETWeightLbskg
15381
750341
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
15381
700318
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
REVERSING PLUGGING E
FRONTLINEreg AC CRANE CONTROL
REVERSING PLUGGING ELEMENTARY DIAGRAM
AC CRANE CONTROL
9
CLASS
LEMENTARY DIAGRAM
CLASS
FRONTLINE
10
CLASS
CLASS
APPROXIMATE DIMENSIOSINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380VHin
mm
HOISTClasses6420 amp6422
40 3048
1219
80 6048
1219
125 10048
1219200 150
NOT A300 200
HOISTClasses6421 amp6426
ampBridge orTrolleyClass6426
40 3048
1219
80 6048
1219
125 10048
1219
NOT A200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSMOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
Win
mm
Cin
mm
NETWeightLbskg
Win
mm
Cin
mm
SINGLE MOTOR CONTROL69
175312305
52523848
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL69
175312305
50022748
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Din
mm
NETWeightLbskg
15381
750341
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
15381
700318
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
10
CLASS
CLASS
APPROXIMATE DIMENSIOSINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380VHin
mm
HOISTClasses6420 amp6422
40 3048
1219
80 6048
1219
125 10048
1219200 150
NOT A300 200
HOISTClasses6421 amp6426
ampBridge orTrolleyClass6426
40 3048
1219
80 6048
1219
125 10048
1219
NOT A200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSMOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
Win
mm
Cin
mm
NETWeightLbskg
Win
mm
Cin
mm
SINGLE MOTOR CONTROL69
175312305
52523848
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL69
175312305
50022748
121969
175369
175312305
70031848
121969
175369
175312305
70031848
121969
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Din
mm
NETWeightLbskg
15381
750341
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
15381
700318
15381
900409
15381
900409
SEE NARROW WIDTH DIMENSIONS
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
APPROXIMATESINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380Vmm
HOIST(All Classes)and Bridge
Trolley
40 30
80 601727
125 1001727
200 1501981
300 2001981
CLASS 6426Bridge and
Trolleyonly
40 30
80 601727
125 1001727
200 150
300 200
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSAND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
ENCLOSED TYPE
OPEN TYPE
Hin
mm
Win
mm
Cin
mm
NETWeightLbskg
Hin
mm
SINGLE MOTOR CONTROL- - - - -
681727
631600
12305
70031868
172768
172763
160012305
70031868
172778
198177
195615381
130059078
198178
198177
195615381
130059078
1981DUPLEX MOTOR CONTROL
- - - - -68
172775
190512305
100045468
172768
172775
190512305
100045468
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
CLASS6420642164226426CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
Win
mm
Din
mm
NETWeightLbskg
- -63
160015381
900409
631600
15381
900409
771956
17482
1800817
771956
17482
1800817
- -75
190515381
1400635
751905
15381
1400635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
12
CLASS
WITH SQUARE DGENERAL INFORMATION
Class 6435 controllers are recommended for used withThe hoist controllers are of the reversing dynamic lowering type whenhoist type when used on cranes with mechanical load brakestravel controls are designed for use with rectifier operated dc brakes or solenoid operated ac brakes
The standard single motor reversing hoist controller consists of equipment for afrequency relay plugging The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorreversing plugging controller with one additional type S three pole contactorprovided (CR) and a pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consistsof
1mdashTwo pole control molded case switch (MCB)1mdashThree pole magnetic main line circuit breaker with padlock clip
(LCB)2mdashType S three-pole directional contactors with mechanical
interlock (F R)3mdashType S three-pole acceleration contactors (including one for
plugging) (1A 2A P)2mdashPneumatic timing acceleration units (1A 2A)1mdashType SZF frequency relay for plugging (PR)1mdash460230 to 115 volt fused control circuit transformer (1mdashControl Circuit Rectifier (RECT)1mdashUndervoltage relay (UV)3mdashMagnetic inverse time overload relays (1OslashL 2OslashL 3OslashL1mdashSZF power loss protection relay circuit (SPR 2RECT 2MOV2RES)
Volts5060Hz
CraneRating
ContactorMaxAmperes
MaxHp
Primary SecondaryREVERSING AC
38067 100 30133 199 60
46067 100 40133 199 80
38067 100 30133 199 60
46067 100 40133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
38067 100 30133 199 60
46067 100 40133 199 80
Select controller based on horsepower and rated primary and secondary current For
ORDERING INFORMATION REQUIRED
1 Class2 Type3 Motor Horsepower
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORSreg
GENERAL INFORMATIONHOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives of general-purposedynamic lowering type when used on cranes without mechanical load brakes and are of the reversing
hoist type when used on cranes with mechanical load brakes The travel controllers are of the reversing plugging type Both the hoist and thefor use with rectifier operated dc brakes or solenoid operated ac brakes
BRIDGE OR TROLLEYThe standard single motor reversing hoist controller consists of equipment for a single motor reversing plugging controller
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motorS three pole contactor provided for dynamic lowering (DB) one additional control relay
pneumatic timing delay is deleted (IA)NOTE DUPLEX CONTROLLERS ARE NOT AVAILABLE
controller consists
Three pole magnetic main line circuit breaker with padlock clip
contactors with mechanical
(including one for
5 volt fused control circuit transformer (CTR)
1OslashL 2OslashL 3OslashL)SZF power loss protection relay circuit (SPR 2RECT 2MOV and
CLASS 8502 TYPE S CONTACTORS PNEUMATOC TIMING ACCELERATION CLASS 8501 TYPE SZF FREQUENCY RELAY FOR
PLUGGING
NEMAContactor
Size
NoSpeedPoints
OpenType
General PurposeEnclosure NEMAType 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL2 4 DOH71 DSH713 4 EOH71 ESH712 4 DOH71 DSH713 4 EOH71 ESH71REVERSING HOIST CONTROL2 4 DOH76 DSH763 4 EOH76 ESH762 4 DOH76 DSH763 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL2 4 DOR76 DSR763 4 EOR76 ESR762 4 DOR76 DSR763 4 EOR76 ESR76
Select controller based on horsepower and rated primary and secondary current For explanation refer to Controller Ratings section of
ORDERING INFORMATION REQUIRED
4 Motor Primary Rated Voltage and Current5 Motor Secondary Rated Voltage and Current6 Controller Modifications Specify Form Numbers
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008
purpose overhead cranesout mechanical load brakes and are of the reversing
versing plugging type Both the hoist and the
reversing plugging controller but without SZFThe standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORSPNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor EnclosureNEMA Type 3R
DWH71EWH71DWH71EWH71
DWH76EWH76DWH76EWH76
DWR76EWR76DWR76EWR76
refer to Controller Ratings section of Application Data
7 Resistors Services Classification8 Master Switch Type and Form Number
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
WITH CLASSTRAVEL CONTROL
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTOTRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
8502 TYPE S CONTACTORS
CLASS
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
14
CLASS
WITH CLASS SQUARE DREVERSING HOIST
CLASS
FRONTLINEreg AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORSREVERSING HOIST ELMENTARY DIAGRAM
September 2008
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
WITH CLASS SQUARE DDYNAMIC LOWERING HOI
FRONTLINEreg AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTODYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
8502 TYPE S CONTACTORSDIAGRAM
CLASS
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
16
CLASS
APPROXIMATE DIMENSIOCLASS 8502 TYPE S CO
OPEN TYPE
DriveMaximum
HP(Volts)
Open Type
Hin
mm
Win
mm
Hoist orTravel
20(380)
401016
24607
40(460)
401016
24607
40(380)
401016
30762
80(460)
401016
30762
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTSCLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
Cin
mm
NetWeightlbskg
Hin
mm
Win
mm
85216
1506842
106730762
85216
1506842
106730762
10254
2009142
106736914
10254
2009142
106736914
September 2008
ENCLOSED TYPE
Enclosed Type
Din
mm
NetWeightlbskg
15381
300136
15381
300136
15381
385175
15381
385175
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
A set of TABWELDreg resistors are required forapplications
RESISTOR APPLICATION
For resistors mounted in racks unwired ndash refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications
CLASS 6715 RESISTORS
To order an AC acceleration resistor set for use with duplex Cpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V andat 67A
Controller Class EnclosureMotorRating
ControlScheme
Code Type Code Code
6420 A0None N
ldquoHrdquo(HP)
6421 A16422 A2
Open O6426 A6
Hoist6435
A7Nema
1G
ldquoKrdquo(kw)
Travel6435
A8Nema
3RW
CustomerDesign
A99NemaScreenCovers
C
NEMA ClassSpeed Points
System VoltageMotor Rated Voltage
Class 6715
Controller TypeEnclosure
Motor Power
Motor ConfigurationRotor Volts
Rotor Amps
FRONTLINEreg AC CRANE CONTROL
SELECTION AND APPLICATIONe required for each AC motor control The following table is for selecting resistor for all AC motor control
RESISTOR APPLICATION
refer to Class 6715
Class 151 and 152 is recommended for light crane duty
Class 161 and 162 is recommended for standard duty
Class 171 and172 is recommended for severe duty
For explanation of NEMA resistor classifications ndash refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE AC RESISTOR SETTo order an AC acceleration resistor set for use with duplex CONTRA-TORQUE hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and
CLASS 6715 RESISTOR SELECTION TABLE
NEMA DUTYSpeedPoints
NO
SystemVoltage
MotorRated
Voltage
Class Code Code V Code V Code
151 A3 208 2 208 2152 B
161 C
162 D4 380 3 380 3171 E
172 F91 G
5460 4 460 4
92 H
CustomerDesign
CS 575 5 575 56
4 4A2 G 37K C 5Class 6715
AC CRANE CONTROL
17
CLASS
The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel) NEMA 161 duty cycle 5 speedpoints system amp motor voltage applied at 460VAC 37kW enclosed in BRG NEMA 1 style rack(s) with rotor voltage at 350V and rotor amps
MotorConfiguration
Ro
tor
Ro
tor
Code Type Code
Simplex S
Vo
lts
Am
psDuplex D
Quadruplex Q
4 D 350V 67A
CLASS
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
18
CLASS
APPROXIMATE NUMBER OCLASS 6715 TABWELD R
This tabulation is based on ECampM resistor designs for use with Class 6420 6421 6422 6426 controllerstabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage andconsult factory with actual motor data
Max HPRating Single
Motor
6420Hoist
161 171 152
5 2 2 1
7 12 2 2 1
10 2 2 1
15 2 3 2
20 3 3 2
25 2 3 2
30 3 3 2
40 3 4 2
50 4 6 2
60 4 6 3
75 6 12 4
100 7 9 4
125 8 12 6
150 12 15 6
200 12 18 9
250 12 21 9
This tabulation is based on ECampM resistor designs for use with Class 6435drive loading and for motors with standard NEMA secondary values of voltage and
MaximumHP
HoistDynamic Lowering
NEMA Class152 162
5 1 175 1 110 1 215 2 220 2 225 2 330 2 340 3 350 3 460 3 475 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services Crequirements of NEMA service classifications I (CMAA Sspeed point modification Form M3
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARSCLASS 6715 TABWELD RESISTOR SECTIONS (265rdquo LONG)
resistor designs for use with Class 6420 6421 6422 6426 controllers and is for estimatetabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current For act
6421Hoist
6422Hoist
162 172 161 171 152
1 1 2 2 1
1 2 2 2 1
2 2 3 3 1
2 2 3 4 2
2 2 4 5 2
2 3 4 6 2
2 3 5 7 2
2 3 6 7 3
2 4 7 9 3
3 4 8 9 3
4 6 9 13 4
5 7 12 18 4
6 9 14 21 7
6 9 18 30 9
9 12 24 36 9
12 15 30 42 12
r designs for use with Class 6435 controller and is for estimate only This tabulation is fordrive loading and for motors with standard NEMA secondary values of voltage and current For actual quantities consult factory
HoistReversing
TravelReverse Plugging
NEMA Class NEMA Class152 162 1521 1 11 1 11 1 11 2 11 2 22 3 22 3 33 3 33 4 33 4 44 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B) to meet theervice classifications I (CMAA Service Classifications A1 C D E and F) the controller must be priced with the 5
September 2008
STANDARS
estimate only Thiscurrent For actual quantities
6426Hoist Bridge or Trolley
162 172
1 1
1 1
1 2
2 2
2 2
2 3
3 3
3 4
4 4
4 4
4 5
6 9
9 9
9 12
12 15
15 18
This tabulation is for typicalFor actual quantities consult factory
TravelReverse Plugging
NEMA Class162
11222334456
lassification II (CMAA service classifications A2 and B) to meet theE and F) the controller must be priced with the 5th
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VGMaster Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420556
642156
642256
6426556
Motion Speed PointsHoist
(Dynamic Lowering)45
Hoist(Reversing)
45
Travel(Reverse Plugging)
45
Refer to Class 9004 catalog for more information
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CGMaster Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1VG9
VG12
B1VG12VG16
D1VG12VG16
A1VG9
VG12
CONTROL 6435Form MA VM
A2AG9 VG9AG9 VG9
A3AG6 VG6AG9 VG9
A3AG6 VG6AG9 VG9
Refer to Class 9004 catalog for more information
AC CRANE CONTROL
19
CLASS
Class 9004 Type CGMaster Switch
CM TYPE
CG12CG12CG12CM16CG12CG16
CG12CG12
VM CMVG9 CG8VG9 CG12VG6 CG6VG9 CG8VG6 CG6VG9 CG8
CLASS
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
20
CLASS
GENERALMANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits exOHSA requirements for a crane disconnect switchThe standard disconnect switch consists of
3mdashClass 8503 Type M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electricalinterlocks are included for indicating lights
1mdashTwo pole control molded case switch with padlock clip (1mdash460380230 to 255 volt fused control circuit transformer (1mdashIntermediate relay (CR)1mdashClass 9999AI1 Arc Suppressor
Volts5060Hz
NEMAContactor
Size
MaxAmperes
380or
460
4 1505 3006 6008 1350
Form
F30A
3 Main Line Power FusesStart-Stop Push Button
X11Additional Control CircuitNC interlocks can be added
A3 ldquoOnOffrdquo PushbuttonP1 Red ldquoOnrdquo Pilot LightP2 Green ldquoOffrdquo Pilot LightT12 200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer
PILOT DEVICESThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ra
DISCONNEWhen applied to cranes the continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
ORDERING INFORMATION REQUIRED1 Class2 Type3 Voltage4 Controller Modifications Specify Form
CLASS
FRONTLINEreg AC CRANE CONTROL
GENERAL INFORMATIONMANUAL MAGNETIC DISCONNECTS SWITCHES
etic disconnect switch is used for protecting electrical crane circuits except lifting magnet circuits The disconnect meets
ype M form Y781 (with silver faced power contacttips) SPNO contactors The contactors are mechanically tiedOne normally open and one normally closed electrical
case switch with padlock clip (CMCS)volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTSFROM CLOSING WHEN HANDLE IS IN OFFPOSITION
CONTACTORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
Amperes
Enclosures
General PurposeNEMA Type 1 gasketed
Dusttight NEMA Type 12Outdoor NEMA Type 3R
MFS12 MFA12MGS12 MGA12MHS12 MHA12MKS12 MKA12
MODIFICATIONSDescription
Main Line Power FusesStop Push Button
Additional Control Circuit Interlocks A maximum of 4 NONC interlocks can be added
Offrdquo PushbuttonRed ldquoOnrdquo Pilot LightGreen ldquoOffrdquo Pilot Light200VA Additional Transformer Capacity
Class L fuse mounting is standard Customer is to supply fuse rating
PILOT DEVICES SELECTIONThe pilot devices should be selected so the current rating is adequate for controlling the disconnect switch For coil currents9998 Coil Data catalog sheets An arc inhibitor may be required depending upon the ratings of the pilot device
DISCONNECT SWITCH SELECTIONcontinuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated current
required by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008
t lifting magnet circuits The disconnect meets
AM OPERATOR PREVENTS CONTACTORFROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BYHANDLE ON THE ENCLOSURE
currents refer to Class
continuous ampere rating of the disconnect switch shall not be less than 50 percent of the total rated currentrequired by all motors on the crane nor less than 75 percent of the rated motor current required by any single crane motion
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINEreg AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
AGRAM
CLASS
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
22
CLASS
APPROXIMATE DIMESION
NEMASize
ContinuousAmpereRating A B C D
4 15018457
5127
8203
19483
5 30014356
3589
45114
28711
6 60018457
5127
8203
19483
8 135014356
5127
8203
28712
CLASS
FRONTLINEreg AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19483
30762
36914
2864727
315800
33838
3589
16229
36914
28711
33838
36914
267678
345876
36914
7178
72183
36914
19483
421067
421067
322818
4351105
451143
3589
10483
421067
28712
57838
441118
363922
345864
36914
70178
59137
741275
September 2008
M N
NetWeight
36914
15381
21096
36914
20508
235107
421067
20508
285130
741275
28508
300138
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex)control primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets ofpower resistors are also required
Four motors connected in parallel (quadruplex)necessary to double the duplex controller price given for twomotors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets opower resistors are required
CONTROLLERSNarrow width controllers ndash Most controllers ara narrow width construction These controllers when compared tostandard controllers are reduced width and increased height Fordetails see controller modifications and controller dimension
CONTROLLER MODIFICAT
Form Description
D6 Motor Isolating Circuit Breakers
B5 Brake Relay Reverse Plugging Controller Only
Y17 Arc Inhibitors Pendant Operated Controller
G95 Miniature Voltmeter Panel Mounted
G91 Miniature Ammeter Panel Mounted
E18 Narrow Width Panel
M24Substitute Type SZF Frequency Relay For ST1 StaticAcceleration Timers
H18Cabinet Space Heater Controlled By Interlock From MContactor
For Duplex Controllers For Duplex controllers multiply price by 2
1 Class2 Type3 Motor Horsepower4 Motor Primary Rated Voltage and Current
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVESTwo motors connected in parallel (duplex) ndash One set of motorcontrol primary equipment and two sets of motor controlsecondary equipment are required in the controller Two sets of
Four motors connected in parallel (quadruplex) ndash It islex controller price given for two
motors in parallel One set of motor control primary and four setsof motor control secondary equipment are required Four sets of
CONTROLLERSMost controllers are also available in
a narrow width construction These controllers when compared tostandard controllers are reduced width and increased height For
see controller modifications and controller dimension
CONTROLLER MStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of theother motor The brakes of the motor not in service are stillreleased electrically
FORM G95 lists a 3 frac12rdquo square miniature voltmeter to monitor onephase of motor primary voltage
FORM G9 lists a 3 frac12rdquo square miniature ammeter to monitor onephase of motor primary current Current transformersform are supplied Form G9 for motors above 10 HP20 HP 460 volts
CONTROLLER MODIFICATIONS
Brake Relay Reverse Plugging Controller Only
Arc Inhibitors Pendant Operated Controller
Substitute Type SZF Frequency Relay For ST1 Static
Cabinet Space Heater Controlled By Interlock From M
APPLICATION DATACLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HPRATING
Brake Size
900 RMP Motors
Light DutyServices
SevereDutyServices
7 12 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707200 708250 708300 708
ORDERING INFORMATION REQUIRED
5 Motor Secondary Rated Voltage andCurrent6 Controller Modifications Specify FormNumbers
7 Resistors Services Classification8 Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
CLASS
CONTROLLER MODIFICATIONSStandard controllers come equipped with the components listedSpecial features to be added to standard controllers are identifiedby Form number Most modifications are self explanatory
list motor isolation circuit breakers for use on duplexcontrollers For operation of the drive on one motor the motorline and connect breakers will disconnect one motor from the lineand connect the frequency relays to the power resistors of the
motor The brakes of the motor not in service are still
lists a 3 frac12rdquo square miniature voltmeter to monitor one
lists a 3 frac12rdquo square miniature ammeter to monitor oneCurrent transformers with this
for motors above 10 HP 230 volt and
PPLICATION DATACLASS 6420 EDDYMAG HOIST
-FLOOR MOUNTED BRAKE
1200 RMP MotorsSevereDutyServices
Light DutyServices
SevereDutyServices
704 703 703
704 703 704
705 704 704
705 704 705
705 705 705
706 705 705
706 705 706
706 706 706
707 706 706
707 706 706
707 707 707
707 707 707
708 707 707708 707 708708 708 708--- 708 708
7 Resistors Services Classification8 Master Switch Type and Form Number
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
24
CLASS
CLASS
CRANE HOOK SPEED VS
CLASS 6421DYNAMIC LO
FIRST
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
PED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAGreg
CLASS 6421DYNAMIC LOWERING HOIST
FIRST
SECOND
THIRD
FOURTH
FIFTH
FIRST
SECOND
THIRD
FOURTH
FIFTH
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
SECOND
THIRDFOURTH
FIFTH
FIRST
FIRST
SECOND amp THIRD
40 60 80 100 120 140 160 180
LOAD PERFORMANCE IN OF SYNCHRONOUS SPEED
September 2008
200
FIFTH
180 200
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
CRANE HOOK SPEEDCLASS 6422 CONTRA
CLASS 6426
SECONDFIRST
FOURTH
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
O
FSY
NC
HR
ON
OU
SSP
EED
FIRST
0
10
20
30
40
50
60
70
80
90
100
0 20 40
HO
OK
SPEE
DIN
SY
NC
HR
ON
OU
SSP
EED
FRONTLINEreg AC CRANE CONTROL
APPLICATION DATACRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUEreg
CLASS 6426 REVERSING HOIST CONTROL(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST amp SECOND
SECOND
THIRD
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUS SPEED
SIXTH
SECOND
THIRD
FOURTH
FIFTH
60 80 100 120 140 160 180
LOAD SPEED IN OF SYNCHRONOUSE SPEED
25
CLASS
CLASS
FIFTH
AUTOMATIC
FIRST amp SECOND
180 200
180 200
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
26
CLASS
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switchradio controlReversing hoistsmechanical load brake gearboxAll other hoist stylesgearbox Best and critical positioning controlrequires E
ResistorsAcceleration resistor setSize based on HP amp duty cycle
Mo
tor
Perf
orm
an
ce
General
Velocity and acceleration is load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
More abrupt speed point
Slowdown
Travel Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
Hoist OFF point slowdown and braking withEddy-Current brakeDB circuitry
OFF Point
Travel No OFF point braking via control
Hoist OFF point braking by Eddybrake CONTRA
Reversing
Travel Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allowsoperation
Hoist Drive is stopped before each changein direction
Power ConsumptionPower dissipated in rotor resistors inspeed points
Component Wear
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Motors Encoders
Requires wound rotor motorNo encoder feedback
Motor blower not typically requiredoperation at reduced motor velocity as fulltorque is not available at zero speed
FRONTLINEreg AC CRANE CONTROL
AC CONTACTOR CONTROL vs DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor rectifier operatedbrake(s) control circuit and or power limitswitches master switch and pendant orradio controlReversing hoists require worm gear ormechanical load brake gearbox
hoist styles require standardgearbox Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limitpendant or radio controlOpen loop hoist controls require worm gear ormechanical load brake gearboxClosed loop hoist controlswith motor encoder feedback
Acceleration resistor set requiredSize based on HP amp duty cycle
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration is load dependantVelocity and acceleration are minimally (open(closed loop) load dependant
Resistor tap and wiring changes are requiredto adjust speeds in the field
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
More abrupt speed point transitions Smooth speed point transitions
Slowdown via Reverse Pluggingdeceleration relay controlled with resistorsto limit current and torque
OFF point slowdown and braking withurrent brake CONTRA-TORQUEreg or
DB circuitry
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
No OFF point braking via control
OFF point braking by Eddy-CurrentCONTRA-TORQUEreg or DB circuitry
OFF point Dynamic Braking (DB)deceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Reversing plugging decelerationrelay controlled with resistors to limit currentand torque Allows reacceleration after relayoperation
Drive is stopped before each changein direction
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speedachieved
Power dissipated in rotor resistors in lowspeed points
Uses less power at reduced velocity and duringacceleration
Acceleration contactors make amp break rotorcurrent at each speed changeDirectional contactors make amp break statorcurrent when starting amp reversingContactors tips coils etc require periodicinspection and replacement
Power contactors eliminatedMotor current switched by solidSpare drive recommended
Requires wound rotor motorNo encoder feedback required
Inverter-duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Motor blower not typically required foroperation at reduced motor velocity as fulltorque is not available at zero speed
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and highduty cycles
September 2008
Frequency Drive
duty squirrel cage wound rotor or standard dutysquirrel cage motor rectifier operated brake(s) controlcircuit and or power limit switches master switch
require worm gear ormechanical load brake gearbox
require standard gearbox butwith motor encoder feedback
Dynamic braking resistor set only sized based oninverter size fewer resistor banks required
Velocity and acceleration are minimally (open loop) or not(closed loop) load dependant
Velocity amp acceleration are programmed for each speedpoint field adjustable through keypad or PC
Smooth speed point transitions
Slowdown via DB resistors on DC bus withprogrammable deceleration ramp
OFF point Dynamic Braking (DB) with programmabledeceleration ramp between all points with load floatingto resume motion without waiting for brake to release
Slowdown with DB (see Slowdown amp OFF)Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity and during
Power contactors eliminatedMotor current switched by solid-state componentsSpare drive recommended
duty squirrel cage motor preferred Load filterrequired for use with wound rotor or standard dutysquirrel cage motors AIST Hoists (closed loop) usemotor encoder feedback for precise handling
Full torque (full current) at slow and zero velocity ispossible As a result motor blower may be requiredwhen operating at reduced velocity with full load and high
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
September 2008 FRONTLINE
CLASS 5010 WB DRUM BRAKES
AIST rated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Hold drive stationary when motor is off
Available in 8rdquo to 30rdquo wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19rdquo 23rdquo and 30rdquo brake sizes
Available with optional self-adjuster
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
AIST rated and suitable for all crane classes
Used on bridge and trolley (horizontal travel) drives
Provide fixed holding torque for parking
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000
Stopping torque ratings up to 300 850 and 1500
Available for AC or DC control systems
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL(Contactor) CONTROLS
Hoist drive styles include Eddy-Current Brakeand Reversing Hoist controls
Reversing Plugging control for bridge and trolley (travel) drives
Meets NEMA Service Classification I
Available in NEMA contactor sizes 2 through 6
Numerous modifications available
Uses Class 8503 Type M Line-ARCreg contactors static timers
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHAamp NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical amp electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWNreg
HOIST POWER LIMIT SWITCHES
Final safety limits for hoist upper travel
Interrupts motor power directly
Available in ratings up to 500HP at 230VDC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER
FRONTLINEreg AC CRANE CONTROL
ated and suitable for all crane classes
Spring set electrically released DC drum type
Available for AC operation with brake rectifier controller
Corrosion resistant pins are standard on all brake sizes
andard on 19rdquo 23rdquo and 30rdquo brake sizes
CLASS 5060 ADJUSTABLE TORQUE DRUM BRAKES
ated and suitable for all crane classes
travel) drives
Provide electrically controlled adjustable torque for stopping
Available in 10rdquo 13rdquo and 16rdquo wheel diameters
Parking torque ratings up to 200 550 and 1000 ft-lbs respectively
Stopping torque ratings up to 300 850 and 1500 ft-lbs respectively
CLASS 6420 to CLASS 6426 AC CONSTANT POTENTIAL
Current Brake CONTRA-TORQUEreg AC Dynamic Lowering
bridge and trolley (travel) drives
Available in NEMA contactor sizes 2 through 6 through 300HP for single or multiple motors
contactors static timers and frequency relays for acceleration
Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
crane disconnect switch
ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by the enclosure handle
Mechanical amp electrical interlocks prevent switch operation with handle in the OFF position
HOIST POWER LIMIT SWITCHES
to 500HP at 230VDC or up to 400HP at 460VAC and 550VAC
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
Crane Control Selection GuideFor more details please see our crane control catalog on-line at wwwECandMnet
Please visit our website for additional details onDC MILL DUTY CONTACTOR CONTROL DIGITAL DC DRIVES
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
AND OTHER MILL DUTY CONTROL COMPONENTS27
CLASS
Available auxiliary contacts set to operate prior to main contacts for variable frequency hoist applications
DC DISCONNECT SWITCHES DC MAGNET CONTROL DC REDUCED VOLTAGE STARTERSMASTER SWITCHES MILL DUTY RELAYS OVERLOAD RELAYS AC CONTACTORS
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
FRONTLINE
28
CLASS
FRONTLINEreg AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
copyCopyright The Electric Controller and Manufacturing Company LLCPrinted in the USA
SEE SEPARATE PRICE SHEET OR CONTACTECampM FOR PRICE AND LEAD-TIME ATWWWECandMNET OR CALL 803-874
September 2008
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922
copyCopyright The Electric Controller and Manufacturing Company LLC 2007
SEE SEPARATE PRICE SHEET OR CONTACTTIME AT
874-3922