September, 2008 FRONTLINE

AC CRANE CONTROL
FRONTLINE

AC CRANE CONTROL
AC CRANE CONTROL
CONTENTS
Description
Type M Contactors
EDDYMAG

Hoist
AC Dynamic Lowering Hoist
CONTRA-TORQUE

Hoist
Reversing Plugging
Dimensions
Modifications and Applications
Type S Controls
Dimensions
Resistor Selection
Master Switches
Disconnect Switches
Manual Magnetic
AC CRANE CONTROL
CLASS
o42
AC CRANE CONTROL
CONTENTS
Class Page
6420 2-3
6421 4-5
6422 6-7
6426 8-9
642/1/2/6 10-11
642/1/2/6 23-25
6435 12-15
6435 16
6715 17
9004 19
6440 20-22
Class
6420, 6421
6422, 6426
6435, 6440
May, 2008
FRONTLINE
2
CLASS
o42
GENERAL INFORMATION
Class 6420 reversing EDDYMAG

controllers 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
operated ac brakes.
The standard single motor reversing EDDYMAG

controller
consists of:
1Two pole control molded case switch (CMCS)
1Three pole magnetic main line circuit breaker with padlock clip
LCB)
2Type M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H, L)
1Type M two-pole main contactor (M)
5 or 6Type M two-pole acceleration contactors
(1A, 2A, 3A, 4A, 5A, 6A)
2 or 3Type ST1 static acceleration timers (3AR, 4AR,
1460/380/230 to 255 volt fused control circuit transformer
(CTR)
1Control Circuit Rectifier (RECT)
1Type KFO under voltage relay (UV)
1Pneumatic timing transition relay (TR)
1Control relay to detect loss of eddy current brake excitation
(AC/DC)
1Set of static eddy current brake control equipment (ECBM)
3Type AO magnetic inverse time overload relays
(1L, 2L, 3L)
1Type SZF acceleration relay (5AR)
1SZF power loss protection relay circuits
(SPR, 2RECT, 2MOV, 2RES)
Voltage
3
50/60Hz
Crane
Rating
NEMA
Contactor
Size
Max
Amperes
Max
Hp
Primary Secondary
380
67 30 2 2
133 60 3 3
200 100 4 4
400 150 5 5
400 200 5 5
460
67 40 2 2
133 80 3 3
200 125 4 4
400 200 5 5
400 300 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 five
These controllers have seven speed points available but are used with six
ORDERING INFORMATION REQUIRED: See Page 23
MODIFICATIONS: See Page
FRONTLINE

AC CRANE CONTROL
GENERAL INFORMATION
EDDYMAG

HOIST SERVICE
controllers 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 SPEEDS
FOR ALL LOADS
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CONTACTORS
CLASS 7001 TYPE ST1 STATIC ACCELERATION TIMERS
REQUIRES EDDY CURRENT ELECTRIC LOAD BRAKE
No.
Speed
Points
Open
Type
General Purpose
Enclosure NEMA
Type 1 Gasketed
Outdoor Enclosure
NEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5* DOH70 DSH70 DWH70
5* EOH70 ESH70 EWH70
5* FOH70 FSH70 FWH70
5* GOH70 GSH70 GWH70
6 GOH90 GSH90 GWH90
5* DOH70 DSH70 DWH70
5* EOH70 ESH70 EWH70
5* FOH70 FSH70 FWH70
5* GOH70 GSH70 GWH70
6 GOH90 GSH90 GWH90
Select controller based on horsepower and rated primary and secondary current. For explanation, refer to Controller Ratings section of Application D
ts 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 23
See Page 24
APPLICATION INFORMATION:
DIMENSIONAL INFORMATION:
September, 2008
controllers 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 brakes or solenoid
AND LOWERING SPEEDS
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
TYPE ST1 STATIC ACCELERATION TIMERS
S EDDY CURRENT ELECTRIC LOAD BRAKE
Outdoor Enclosure
Dusttight
Enclosure NEMA
Type 12
DAH70
EAH70
FAH70
GAH70
GAH90
DAH70
EAH70
FAH70
GAH70
GAH90
Controller Ratings section of Application Data.
point master switches, the last acceleration point being relay controlled.
ches, the last acceleration point being relay controlled.
APPLICATION INFORMATION: See Pages 23-25
DIMENSIONAL INFORMATION: See Pages 10&11
September, 2008 FRONTLINE
EDDYMAG
FRONTLINE

AC CRANE CONTROL
EDDYMAG

HOIST ELEMENTARY
AC CRANE CONTROL
3
CLASS
o42
FRONTLINE
4
CLASS
o42
AC DYNAMIC LOWERING
GENERAL INFORMATION
Class 6421 reversing 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
The standard single motor reversing dynamic lowering
consists of:
1Two pole control molded case switch (CMCS)
1Three pole magnetic main line circuit breaker with padlock clip
(LCB)
4Type M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H, L, DB, M)
5 or 6Type M two-pole acceleration contactors
(1A, 2A, 3A, 4A, 5A, 6A)
3, 4 or 5Type SZF static acceleration relays
(2AR, 3AR, 4AR, 5AR)
1460/380/230 to 255 volt fused control circuit transformer
(CTR)
1Control Circuit Rectifier (RECT)
1Type KFO under voltage relay (UV)
1Brake relay (BR)
1Pneumatic timing transition relay (TR)
3Type AO magnetic inverse time overload relays
(1L, 2L, 3L)
1SZF power loss protection relay circuits
(SPR, 2RECT, 2MOV, 2RES)
Volts
3
50/60Hz
Crane
Rating

NEMA
Contactor
Size
Max
Amperes
Max
Hp
Primary Secondary
380
67 30 2 2
133 60 3 3
200 100 4 4
400 150 5 5
400 200 5 5
460
67 40 2 2
133 80 3 3
200 125 4 4
400 200 5 5
400 300 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 5point master switches, the last a

These controllers have seven speed points available but are used with 6point master switches, the last acceleratio
ORDERING INFORMATION REQUIRED: See Page 23
MODIFICATIONS: See Page 24
CLASS
o42
FRONTLINE

AC CRANE CONTROL
AC DYNAMIC LOWERING
GENERAL INFORMATION
HOIST SERVICE
reversing 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 FOR
DYNAMIC LOWERING
SUITABLE FOR APPLICATIONS NOT REQUIRING SLOW
LOWERING SPEED
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
No.
Speed
Points
Open
Type
General Purpose
Enclosure NEMA
Type 1 Gasketed
Outdoor Enclosure
NEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5* DOH71 DSH71 DWH71
5* EOH71 ESH71 EWH71
5* FOH71 FSH71 FWH71
5* GOH71 GSH71 GWH71
6 GOH91 GSH91 GWH91
5* DOH71 DSH71 DWH71
5* EOH71 ESH71 EWH71
5* FOH71 FSH71 FWH71
5* GOH71 GSH71 GWH71
6 GOH91 GSH91 GWH91
Select controller based on horsepower and rated primary and secondary current. For explanation, refer to Controller Ratings section of Application D
controllers have six speed points available but are used with 5point master switches, the last acceleration point being relay controlled.
controllers have seven speed points available but are used with 6point master switches, the last acceleration point being relay controlled.
See Page 23
See Page 24
APPLICATION INFORMATION:
DIMENSIONAL 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 Enclosure
Dusttight
Enclosure NEMA
Type 12
DAH71
EAH71
FAH71
GAH71
GAH91
DAH71
EAH71
FAH71
GAH71
GAH91
Application Data.
cceleration point being relay controlled.
n point being relay controlled.
APPLICATION INFORMATION:See Pages 23-25
DIMENSIONAL INFORMATION:See Pages 10&11
September, 2008 FRONTLINE
DYNAMIC LOWERING ELE
FRONTLINE

AC CRANE CONTROL
DYNAMIC LOWERING ELEMENTARY DIAGRAM
AC CRANE CONTROL
5
CLASS
o42
MENTARY DIAGRAM
CLASS
o42
FRONTLINE
6
CLASS
o42
GENERAL
Class 6422 reversing CONTRA-TORQUE

controllers are recommended

mechanical load brakes but with fixed overhauling loads such as bucket crane hoist
operated dc shunt brakes or solenoid operated ac brakes
The standard single motor reversing CONTRA-TORQUE
controller consists of:
1Two pole control molded case switch (CMCS)
1Three pole magnetic main line circuit breaker with padlock clip
(LCB)
2Type M two-pole contactors with mechanical interlock for
hoisting and lowering circuits (H, L)
1Type M two-pole main contactor (M)
5 or 6Type M two-pole acceleration contactors
(1A, 2A, 3A, 4A, 5A, 6A)
5 or 6Type SZF frequency relays
(3AR, 4AR, 5AR, 6AR OS, NH)
1460/380/230 to 255 volt fused control circuit transformer
(CTR)
1Control Circuit Rectifier (RECT)
1Type KFO under voltage relay (UV)
2Pneumatic timing relays for counter-torque and lowering
relays (CTR, LR)
1Pneumatic timing transition relay (TR)
3Type AO magnetic inverse time overload relays
(1L, 2L, 3L)
1SZF power loss protection relay circuits
(SPR, 2RECT, 2MOV, 2RES)
Volts
50/60Hz
Crane
Rating
NEMA
Contactor
Size
Max
Amperes
Max
Hp
Primary Secondary
380
67 30 2 2
133 60 3 3
200 100 4 4
400 150 5 5
400 200 5 5
460
67 40 2 2
133 80 3 3
200 125 4 4
400 200 5 5
400 300 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
These controllers have seven speed points available but are used with 6point master switches, the last acceleration point being rel
ORDERING INFORMATION REQUIRED: See Page 23
MODIFICATIONS: See Page
CLASS
o422
FRONTLINE

AC CRANE CONTROL
CONTRA-TORQUE

GENERAL INFORMATION
HOIST SERVICE
controllers are recommended for use with ac wound rotor motors on crane hoist
but 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.
TORQUE

ine circuit breaker with padlock clip

contactors with mechanical interlock for
volt fused control circuit transformer
and lowering
PROVIDES SLOW LOWERING SPEEDS FOR
OVERHAULING LOADS ONLY
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CONTACTORS
CLASS 8501 TYPE SZF STATIC ACCELERATION TIMERS
No.
Speed
Points
Open
Type
General Purpose
Enclosure NEMA
Type 1 Gasketed
Outdoor Enclosure
NEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5* DOH72 DSH72 DWH72
5* EOH72 ESH72 EWH72
5* FOH72 FSH72 FWH72
5* GOH72 GSH72 GWH72
6 GOH92 GSH92 GWH92
5* DOH72 DSH72 DWH72
5* EOH72 ESH72 EWH72
5* FOH72 FSH72 FWH72
5* GOH72 GSH72 GWH72
6 GOH92 GSH92 GWH92
Select controller based on horsepower and rated primary and secondary current. For explanation, refer to Controller Ratings section of
controllers have six speed points available but are used with 5point master switches, the last acceleration point being relay controlled.
controllers have seven speed points available but are used with 6point master switches, the last acceleration point being relay controlled.
See Page 23
See Page 24
APPLICATION INFORMATION:
DIMENSIONAL INFORMATION:
September, 2008
for use with ac wound rotor motors on crane hoists without
arranged for use with rectifier
LOWERING SPEEDS FOR
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
STATIC ACCELERATION TIMERS
Outdoor Enclosure
Dusttight
Enclosure NEMA
Type 12
DAH72
EAH72
FAH72
GAH72
GAH92
DAH72
EAH72
FAH72
GAH72
GAH92
Controller Ratings section of Application Data.
5point master switches, the last acceleration point being relay controlled.
ay controlled.
APPLICATION INFORMATION: See Pages 23-25
DIMENSIONAL INFORMATION: See Pages 10&11
September, 2008 FRONTLINE
CONTRA
FRONTLINE

AC CRANE CONTROL
CONTRA-TORQUE

ELEMENTARY DIAGRAM
AC CRANE CONTROL
7
CLASS
o42
CLASS
o422
FRONTLINE
8
CLASS
o42
REVERSING PLUGGING
Class 6426 controllers are recommended for used with
The hoist controllers are of the reversing hoist type and are used on cranes with mechanical load brakes. The
reversing plugging type. Both the hoist and the travel controller
operated ac brakes.
The standard single motor reversing hoist controller consists of equipment for a reversing plugging controller
for plugging (PR).
BRIDGE OR TROLLEY SE
The standard single motor reversing controller consists of:
1Two pole control molded case switch (CMCS)
1Three pole magnetic main line circuit breaker with padlock clip
(LCB)
2Type M two-pole contactors with mechanical interlock
1Type 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)
1Type SZF frequency relay for plugging (PR)
1460/380/230 to 255 volt fused control circuit transformer
(CTR)
1Control Circuit Rectifier (RECT)
1Type KFO under voltage relay (UV)
3Type AO magnetic inverse time overload relays
(1L, 2L, 3L)
1SZF power loss protection relay circuit
(SPR, 2RECT, 2MOV, 2RES)
The standard duplex reversing plugging controller consists of the
equipment for a single motor controller with the exception
following equipment is added:
4 or 5Type M two-pole acceleration contactors
(2P, 21A, 22A, 23A, 24A)
3Type AO magnetic inverse time overload relays
(4L, 5L, 6L)
Volts
50/60Hz
Crane
Rating
NEMA
Contactor
Size
Max
Amperes
Max
Hp
Primary Secondary
Primary Secondary
380
67 67 30 2 2
133 133 60 3 3
200 200 100 4 4
400 400 150 5 5
400 400 200 5 5
460
67 67 40 2 2
133 133 80 3 3
200 200 125 4 4
400 400 200 5 5
400 400 300 5 5
380
67 67 30 2 2
133 133 60 3 2
200 200 100 4 3
400 400 150 5 4
400 400 200 5 5
460
67 67 40 2 2
133 67 80 3 2
200 133 120 4 3
400 200 200 5 4
400 400 300 5 5
Select controller based on motor horsepower and rated primary and secondary current. For
Price is for single motor reversing plugging or reversing hoist. For reversing hoist, change the
*These controllers have 6 speed points available but are used with 5point master switches, the last acceleration point being
These controllers have seven speed points available but are used with 6point master swit
ORDERING INFORMATION REQUIRED: See Page 23
MODIFICATIONS: See Page 24
CLASS
o42o
FRONTLINE

AC CRANE CONTROL
REVERSING PLUGGING CONTROL
for 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 the
controllers are arranged for use with rectifier operated dc shunt brakes or solenoid
HOIST SERVICE
The 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 the
for a single motor controller with the exception that the
MILL DUTY CLASS 8503 TYPE M CLAPPER TYPE
CONTACTORS
CLASS 8501 TYPE SZF FREQUENCY ACCELERATION
RELAYS FOR PLUGGING
CLASS 7001 TYPE ST1 STATICACCELERATION TIMERS
No.
Speed
Points
Open
Type
General Purpose
Enclosure NEMA
Type 1 Gasketed
Outdoor Enclosure
NEMA Type 3R
Secondary
SINGLE MOTOR CONTROL
5 DOR76 DSR76 DWR76
5 EOR76 ESR76 EWR76
5* FOR76 FSR76 FWR76
5* GOR76 GSR76 GWR76
6 GOR96 GSR96 GWR96
5 DOR76 DSR76 DWR76
5 EOR76 ESR76 EWR76
5* FOR76 FSR76 FWR76
5* GOR76 GSR76 GWR76
6 GOR96 GSR96 GWR96
DUPLEX MOTOR CONTROL
5 DOR86 DSR86 DWR86
5 EOR86 ESR86 EWR86
5 FOR86 FSR86 FWR86
5* GOR86 GSR86 GWR86
5* GOR106 GSR106 GWR106
5 DOR86 DSR86 DWR86
5 EOR86 ESR86 EWR86
5* FOR86 FSR86 FWR86
5* GOR86 GSR86 GWR86
5* GOR106 GSR106 GWR106
Select controller based on motor horsepower and rated primary and secondary current. For explanation, refer to Controller Ratings section of Application Data
Price 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 controlled.
These controllers have seven speed points available but are used with 6point master switches, the last acceleration point being relay controlled.
See Page 23
See Page 24
APPLICATION INFORMATION:
DIMENSIONAL INFORMATION:
September, 2008
purpose overhead cranes.
panels 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
Dusttight
Enclosure NEMA
Type 12
DAR76
EAR76
FAR76
GAR76
GAR96
DAR76
EAR76
FAR76
GAR76
GAR96
DAR86
EAR86
FAR86
GAR86
GAR106
DAR86
EAR86
FAR86
GAR86
GAR106
Application Data.
APPLICATION INFORMATION: See Pages 23-25
DIMENSIONAL INFORMATION: See Pages 10&11
September, 2008 FRONTLINE
REVERSING PLUGGING E
FRONTLINE

AC CRANE CONTROL
REVERSING PLUGGING ELEMENTARY DIAGRAM
AC CRANE CONTROL
9
CLASS
o42
LEMENTARY DIAGRAM
CLASS
o42o
FRONTLINE
10
CLASS
o42
CLASS
o42
o42
o422
o42o
APPROXIMATE DIMENSIO
SINGLE AND DUPLEX MOTOR CONTROL STANDA
OPEN TYPE
MAXIMUM HP
460V 380V
H
in
mm
HOIST
Classes
6420 &
6422
40 30
48
1219
80 60
48
1219
125 100
48
1219
200 150
NOT A
300 200
HOIST
Classes
6421 &
6426
&
Bridge or
Trolley
Class
6426
40 30
48
1219
80 60
48
1219
125 100
48
1219
NOT A
200 150
300 200
FRONTLINE

AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTS
MOTOR CONTROL STANDARD CONTROLLERS
ENCLOSED TYPE
OPEN TYPE ENCLOSED TYPE
W
in
mm
C
in
mm
NET
Weight
Lbs/kg
W
in
mm
C
in
mm
SINGLE MOTOR CONTROL
69
1753
12
305
525/238
48
1219
69
1753
69
1753
12
305
700/318
48
1219
69
1753
69
1753
12
305
700/318
48
1219
69
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
DUPLEX MOTOR CONTROL
69
1753
12
305
500/227
48
1219
69
1753
69
1753
12
305
700/318
48
1219
69
1753
69
1753
12
305
700/318
48
1219
69
1753
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
September, 2008
RD CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
D
in
mm
NET
Weight
Lbs/kg
15
381
750/341
15
381
900/409
15
381
900/409
SEE NARROW WIDTH DIMENSIONS
15
381
700/318
15
381
900/409
15
381
900/409
SEE NARROW WIDTH DIMENSIONS
September, 2008 FRONTLINE
APPROXIMATE
SINGLE AND DUPLEX
OPEN TYPE
DRIVE
MAXIMUM HP
460V 380V
mm
HOIST
(All Classes)
and Bridge,
Trolley
40 30
80 60
1727
125 100
1727
200 150
1981
300 200
1981
CLASS 6426
Bridge and
Trolley
only
40 30
80 60
1727
125 100
1727
200 150
300 200
FRONTLINE

AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTS
AND DUPLEX MOTOR CONTROL NARROW WIDTH CONTR
.
ENCLOSED TYPE
OPEN TYPE
H
in
mm
W
in
mm
C
in
mm
NET
Weight
Lbs/kg
H
in
mm
SINGLE MOTOR CONTROL
- - - - -
68
1727
63
1600
12
305
700/318
68
1727
68
1727
63
1600
12
305
700/318
68
1727
78
1981
77
1956
15
381
1300/590
78
1981
78
1981
77
1956
15
381
1300/590
78
1981
DUPLEX MOTOR CONTROL
- - - - -
68
1727
75
1905
12
305
1000/454
68
1727
68
1727
75
1905
12
305
1000/454
68
1727
NOT AVAILABLE IN STANDARD DIMENSIONS SEE NARROW WIDTH DIM
AC CRANE CONTROL
11
CLASS
o42
CLASS
6420
6421
6422
6426
CONTROLLERS
ENCLOSED TYPE
ENCLOSED TYPE
W
in
mm
D
in
mm
NET
Weight
Lbs/kg
- -
63
1600
15
381
900/409
63
1600
15
381
900/409
77
1956
17
482
1800/817
77
1956
17
482
1800/817
- -
75
1905
15
381
1400/635
75
1905
15
381
1400/635
SEE NARROW WIDTH DIMENSIONS
FRONTLINE
12
CLASS
o42
WITH SQUARE D
GENERAL INFORMATION
Class 6435 controllers are recommended for used with
The hoist controllers are of the reversing dynamic lowering type when
hoist type when used on cranes with mechanical load brakes.
travel 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 a
frequency relay plugging. The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
reversing plugging controller, with one additional type S three pole contactor
provided (CR) and a pneumatic timing delay is deleted (IA).
NOTE: DUPLEX CONTROLLERS ARE NOT AVAILABLE
The standard single motor reversing plugging controller consists
of:
1Two pole control molded case switch (MCB)
1Three pole magnetic main line circuit breaker with padlock clip
(LCB)
2Type S three-pole directional contactors with mechanical
interlock (F, R)
3Type S three-pole acceleration contactors (including one for
plugging) (1A, 2A, P)
2Pneumatic timing acceleration units (1A, 2A)
1Type SZF frequency relay for plugging (PR)
1460/230 to 115 volt fused control circuit transformer (
1Control Circuit Rectifier (RECT)
1Undervoltage relay (UV)
3Magnetic inverse time overload relays (1L, 2L, 3L
1SZF power loss protection relay circuit (SPR, 2RECT, 2MOV,
2RES)
Volts
50/60Hz
Crane
Rating

Contactor Max
Amperes
Max
Hp
Primary Secondary
REVERSING AC
380
67 100 30
133 199 60
460
67 100 40
133 199 80
380
67 100 30
133 199 60
460
67 100 40
133 199 80
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
380
67 100 30
133 199 60
460
67 100 40
133 199 80
Select controller based on horsepower and rated primary and secondary current. For
ORDERING INFORMATION REQUIRED:
1. Class
2. Type
3. Motor Horsepower
4. Motor Primary Rated Voltage and Current
5. Motor Secondary Rated Voltage and Current
6. Controller Modifications: Specify Form Numbers
CLASS
o435
FRONTLINE

AC CRANE CONTROL
SQUARE D CLASS 8502 TYPE S CONTACTORS

GENERAL INFORMATION
HOIST SERVICE
controllers are recommended for used with ac wound rotor motor on hoist and travel drives, of general-purpose
dynamic 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 the
for use with rectifier operated dc brakes or solenoid operated ac brakes.
BRIDGE OR TROLLEY
The 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 motor
S 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)
1L, 2L, 3L)
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
NEMA
Contactor
Size
No.
Speed
Points
Open
Type
General Purpose
Enclosure NEMA
Type 1 Gasketed
REVERSING AC DYNAMIC LOWERING HOIST CONTROL
2 4 DOH71 DSH71
3 4 EOH71 ESH71
2 4 DOH71 DSH71
3 4 EOH71 ESH71
REVERSING HOIST CONTROL
2 4 DOH76 DSH76
3 4 EOH76 ESH76
2 4 DOH76 DSH76
3 4 EOH76 ESH76
REVESING PLUGGING BRIDGE OR TROLLEY CONTROL
2 4 DOR76 DSR76
3 4 EOR76 ESR76
2 4 DOR76 DSR76
3 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 Current
5. Motor Secondary Rated Voltage and Current
6. Controller Modifications: Specify Form Numbers
7. Resistors Services Classification
8. Master Switch Type and Form Number
September, 2008
purpose overhead cranes.
out mechanical load brakes and are of the reversing
versing plugging type. Both the hoist and the
reversing plugging controller but without SZF
The standard single motor reversing dynamic lowering hoist controller consists of the equipment for a single motor
one additional control relay
LASS 8502 TYPE S CONTACTORS
PNEUMATOC TIMING ACCELERATION
FREQUENCY RELAY FOR
Outdoor Enclosure
NEMA Type 3R
DWH71
EWH71
DWH71
EWH71
DWH76
EWH76
DWH76
EWH76
DWR76
EWR76
DWR76
EWR76
refer to Controller Ratings section of Application Data.
7. Resistors Services Classification
8. Master Switch Type and Form Number
September, 2008 FRONTLINE
WITH CLASS
TRAVEL CONTROL
FRONTLINE

AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTO
TRAVEL CONTROL ELEMENTARY DIAGRAM
AC CRANE CONTROL
13
CLASS
o42
8502 TYPE S CONTACTORS
CLASS
o435
FRONTLINE
14
CLASS
o42
WITH CLASS SQUARE D
REVERSING HOIST
CLASS
o435
FRONTLINE

AC CRANE CONTROL
SQUARE D 8502 TYPE S CONTACTORS
REVERSING HOIST ELMENTARY DIAGRAM
September, 2008
September, 2008 FRONTLINE
WITH CLASS SQUARE D
DYNAMIC LOWERING HOI
FRONTLINE

AC CRANE CONTROL
WITH CLASS SQUARE D 8502 TYPE S CONTACTO
DYNAMIC LOWERING HOIST ELEMENTARY DIAGRAM
AC CRANE CONTROL
15
CLASS
o42
8502 TYPE S CONTACTORS
DIAGRAM
CLASS
o435
FRONTLINE
16
CLASS
o42
APPROXIMATE DIMENSIO
CLASS 8502 TYPE S CO
OPEN TYPE
Drive
Maximum
HP
(Volts)
Open Type
H
in
mm
W
in
mm
Hoist or
Travel
20
(380)
40
1016
24
607
40
(460)
40
1016
24
607
40
(380)
40
1016
30
762
80
(460)
40
1016
30
762
CLASS
o435
FRONTLINE

AC CRANE CONTROL
APPROXIMATE DIMENSIONS AND WEIGHTS
CLASS 8502 TYPE S CONTACTORS
ENCLOSED TYPE
Open Type Enclosed Type
C
in
mm
Net
Weight
lbs/kg
H
in
mm
W
in
mm
8.5
216
150/68
42
1067
30
762
8.5
216
150/68
42
1067
30
762
10
254
200/91
42
1067
36
914
10
254
200/91
42
1067
36
914
September, 2008
ENCLOSED TYPE
Enclosed Type
D
in
mm
Net
Weight
lbs/kg
15
381
300/136
15
381
300/136
15
381
385/175
15
381
385/175
September, 2008 FRONTLINE
A set of TABWELD

resistors are required for

applications.
RESISTOR APPLICATION
For resistors mounted in racks, unwired 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 C
points, system & motor voltage applied at 460VAC, 37kW, enclosed in BRG NEMA 1 style rack(s), with rotor voltage at 350V and
at 67A.
Controller Class Enclosure
Motor
Rating
Control
Scheme
Code Type Code Code
6420 A0
None N
#H
(HP)
6421 A1
6422 A2
Open O
6426 A6
Hoist
6435
A7
Nema
1
G
#K
(kw)
Travel
6435
A8
Nema
3R
W
Customer
Design
A99
Nema
Screen
Covers
C
NEMA Class
Speed Points
System Voltage
Motor Rated Voltage
Class 6715
Controller Type
Enclosure
Motor Power
Motor Configuration
Rotor Volts
Rotor Amps
FRONTLINE

AC CRANE CONTROL
SELECTION AND APPLICATION
e 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 refer to Class 6715
CLASS
CLASS 6715 RESISTORS SELECTION TABLE
EXAMPLE: AC RESISTOR SET
To order an AC acceleration resistor set, for use with duplex CONTRA

-TORQUE hoist (2 motors in parallel), NEMA 161 duty cycle, 5 speed

points, system & 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 DUTY
Speed
Points
NO.
System
Voltage
Motor
Rated
Voltage
Class Code Code V Code V Code
151 A
3 208 2 208 2 152 B
161 C
162 D
4 380 3 380 3 171 E
172 F
91 G
5
460 4 460 4
92 H
Customer
Design
CS 575 5 575 5
6
4 4 A2 G 37K C 5 Class 6715
AC CRANE CONTROL
17
CLASS
o42
. The following table is for selecting resistor for all AC motor control
6715
hoist (2 motors in parallel), NEMA 161 duty cycle, 5 speed
points, system & motor voltage applied at 460VAC, 37kW, enclosed in BRG NEMA 1 style rack(s), with rotor voltage at 350V and rotor amps
Motor
Configuration
R
o
t
o
r
R
o
t
o
r
Code Type Code
Simplex S
V
o
l
t
s
A
m
p
s
Duplex D
Quadruplex Q
4 D 350V 67A
CLASS
o5
FRONTLINE
18
CLASS
o42
APPROXIMATE NUMBER O
CLASS 6715 TABWELD R
This tabulation is based on EC&M resistor designs for use with Class 6420, 6421, 6422, 6426 controllers
tabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and
consult factory with actual motor data.
Max. H.P.
Rating Single
Motor
6420
Hoist
161 171 152
5 2 2 1
7 1/2 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 EC&M resistor designs for use with Class 6435
drive loading and for motors with standard NEMA secondary values of voltage and
Maximum
HP
Hoist
Dynamic Lowering
NEMA Class
152 162
5 1 1
7.5 1 1
10 1 2
15 2 2
20 2 2
25 2 3
30 2 3
40 3 3
50 3 4
60 3 4
75 4 6
NEMA SERVICE CLASSIF
Standard 6435 controllers meet the requirements of NEMA Services C
requirements of NEMA service classifications I (CMAA S
speed point modification, Form M3.
CLASS
o435
FRONTLINE

AC CRANE CONTROL
APPROXIMATE NUMBER OF SEPARATELY MOUNTED STANDARS
CLASS 6715 TABWELD RESISTOR SECTIONS (26.5 LONG)
resistor designs for use with Class 6420, 6421, 6422, 6426 controllers and is for estimate
tabulation is for typical drive loading and for motors with standard NEMA secondary values of voltage and current. For act
6421
Hoist
6422
Hoist
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 for
drive loading and for motors with standard NEMA secondary values of voltage and current. For actual quantities, consult factory.
Hoist
Reversing
Travel
Reverse Plugging
NEMA Class NEMA Class
152 162 152
1 1 1
1 1 1
1 1 1
1 2 1
1 2 2
2 3 2
2 3 3
3 3 3
3 4 3
3 4 4
4 6 4
NEMA SERVICE CLASSIFICATIONS
meet the requirements of NEMA Services Classification II (CMAA service classifications A2 and B). to meet the
ervice classifications I (CMAA Service Classifications A1, C, D, E and F), the controller must be priced with the 5
September, 2008
STANDARS
estimate only. This
current. For actual quantities,
6426
Hoist, 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 typical
For actual quantities, consult factory.
Travel
Reverse Plugging
NEMA Class
162
1
1
2
2
2
3
3
4
4
5
6
lassification II (CMAA service classifications A2 and B). to meet the
E and F), the controller must be priced with the 5
th
September, 2008 FRONTLINE
MASTER SWITCHES AND
Class 9004 Type VG
Master Switch
CLASS 9004 VM OR CM
Control Class Speed Points
6420
5
5
6
6421
5
6
6422
5
6
6426
5
5
6
Motion Speed Points
Hoist
(Dynamic Lowering)
4
5
Hoist
(Reversing)
4
5
Travel
(Reverse Plugging)
4
5
Refer to Class 9004 catalog for more information.
FRONTLINE

AC CRANE CONTROL
GENERAL INFORMATION
MASTER SWITCHES AND MODIFICATIONS
Class 9004 Type CG
Master Switch
CLASS 9004 VM OR CM NEMA 1 ENCLOSED
oints Form VM TYPE
C1
VG9

VG12
B1
VG12
VG16
D1
VG12
VG16
A1
VG9

VG12
CONTROL 6435
Form MA VM
A2
AG9 VG9
AG9 VG9
A3
AG6 VG6
AG9 VG9
A3
AG6 VG6
AG9 VG9
Refer to Class 9004 catalog for more information.
AC CRANE CONTROL
19
CLASS
o42
Class 9004 Type CG
Master Switch
CM TYPE

CG12
CG12
CG12
CM16
CG12
CG16

CG12
CG12
VM CM
VG9 CG8
VG9 CG12
VG6 CG6
VG9 CG8
VG6 CG6
VG9 CG8
CLASS
`4
FRONTLINE
20
CLASS
o42
GENERAL
MANUAL MAGNETIC DISC
The manual magnetic disconnect switch is used for protecting electrical crane circuits, ex
OHSA requirements for a crane disconnect switch.
.
The standard disconnect switch consists of:
3Class 8503 Type M, form Y781 (with silver faced power contact
tips), SPNO contactors. The contactors are mechanically tied.
One normally open and one normally closed electrical
interlocks are included for indicating lights
1Two pole control molded case switch with padlock clip (
1460/380/230 to 255 volt fused control circuit transformer (
1Intermediate relay (CR)
1Class 9999AI1 Arc Suppressor
Volts
50/60Hz
NEMA
Contactor
Size
Max
Amperes
380
or
460
4 150
5 300
6 600
8 1350
Form
F30
A
3 Main Line Power Fuses
Start-Stop Push Button
X11
Additional Control Circuit
/N.C. interlocks can be added
A3 On/Off Pushbutton
P1 Red On Pilot Light
P2 Green Off Pilot Light
T12 200VA Additional Transformer Capacity
Class L fuse mounting is standard. Customer
PILOT DEVICES
The pilot devices should be selected so the current rating is adequate for controlling the disconnect switch. For coil
9998 Coil Data catalog sheets. An arc inhibitor may be required depending upon the ra
DISCONNE
When applied to cranes, the continuous 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.
ORDERING INFORMATION REQUIRED:
1. Class
2. Type
3. Voltage
4. Controller Modifications: Specify Form
CLASS
o44
FRONTLINE

AC CRANE CONTROL
GENERAL INFORMATION
MANUAL 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 contact
tips), SPNO contactors. The contactors are mechanically tied.
One normally open and one normally closed electrical
case switch with padlock clip (CMCS)
volt fused control circuit transformer (CTR)
CAM OPERATOR PREVENTS
FROM CLOSING WHEN HANDLE IS IN OFF
POSITION
CONTACTORS OPERATED REMOTELY OR BY
HANDLE ON THE ENCLOSURE
Amperes
Enclosures
General Purpose
NEMA Type 1 gasketed
Dusttight NEMA Type 12
Outdoor NEMA Type 3R
MFS12 MFA12
MGS12 MGA12
MHS12 MHA12
MKS12 MKA12
MODIFICATIONS
Description
Main Line Power Fuses
Stop Push Button
Additional Control Circuit Interlocks. A maximum of 4 N.O.
/N.C. interlocks can be added
Off Pushbutton
Red On Pilot Light
Green Off Pilot Light
200VA Additional Transformer Capacity
Class L fuse mounting is standard. Customer is to supply fuse rating.
PILOT DEVICES SELECTION
The pilot devices should be selected so the current rating is adequate for controlling the disconnect switch. For coil currents,
9998 Coil Data catalog sheets. An arc inhibitor may be required depending upon the ratings of the pilot device.
DISCONNECT SWITCH SELECTION
continuous 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 CONTACTOR
FROM CLOSING WHEN HANDLE IS IN OFF
ORS OPERATED REMOTELY OR BY
HANDLE 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 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 FRONTLINE
MANUAL MAGNETIC DISC
FRONTLINE

AC CRANE CONTROL
MANUAL MAGNETIC DISCONNECT ELEMENTARY DIAGRA
AC CRANE CONTROL
21
CLASS
o42
AGRAM
CLASS
o44
FRONTLINE
22
CLASS
o42
APPROXIMATE DIMESION
NEMA
Size
Continuous
Ampere
Rating A B C D
4 150
18
457
5
127
8
203
19
483
5 300
14
356
3.5
89
4.5
114
28
711
6 600
18
457
5
127
8
203
19
483
8 1350
14
356
5
127
8
203
28
712
CLASS
o44
FRONTLINE

AC CRANE CONTROL
APPROXIMATE DIMESIONS AND WEIGHTS
D E F G H J K L M
19
483
30
762
36
914
28.64
727
31.5
800
33
838
3.5
89
16
229
36
914
28
711
33
838
36
914
26.7
678
34.5
876
36
914
7
178
7.2
183
36
914
19
483
42
1067
42
1067
32.2
818
43.5
1105
45
1143
3.5
89
10
483
42
1067
28
712
57
838
44
1118
36.3
922
34.5
864
36
914
7.0
178
5.9
137
74
1275
September, 2008
M N
Net
Weight
36
914
15
381
210
96
36
914
20
508
235
107
42
1067
20
508
285
130
74
1275
28
508
300
138
September, 2008 FRONTLINE
MULTIMOTOR DRIVES
Two motors connected in parallel (duplex)
control primary equipment and two sets of motor control
secondary equipment are required in the controller. Two sets of
power resistors are also required.
Four motors connected in parallel (quadruplex)
necessary to double the duplex controller price given for two
motors in parallel. One set of motor control primary and four sets
of motor control secondary equipment are required. Four sets o
power resistors are required.
CONTROLLERS
Narrow width controllers Most controllers ar
a narrow width construction. These controllers, when compared to
standard controllers, are reduced width and increased height. For
details, 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
M24
Substitute Type SZF Frequency Relay For ST1 Static
Acceleration Timers
H18
Cabinet Space Heater Controlled By Interlock From M
Contactor
For Duplex Controllers
* For Duplex controllers multiply price by 2.
1. Class
2. Type
3. Motor Horsepower
4. Motor Primary Rated Voltage and Current
FRONTLINE

AC CRANE CONTROL
APPLICATION DATA
MULTIMOTOR DRIVES
Two motors connected in parallel (duplex) One set of motor
control primary equipment and two sets of motor control
secondary equipment are required in the controller. Two sets of
Four motors connected in parallel (quadruplex) It is
lex controller price given for two
motors in parallel. One set of motor control primary and four sets
of motor control secondary equipment are required. Four sets of
CONTROLLERS
Most controllers are also available in
a narrow width construction. These controllers, when compared to
standard controllers, are reduced width and increased height. For
see controller modifications and controller dimension.
CONTROLLER M
Standard controllers come equipped with the components listed.
Special features to be added to standard controllers are identified
by Form number. Most modifications are self
FORM D6 list motor isolation circuit breakers for use on duplex
controllers. For operation of the drive on one motor, the motor
line and connect breakers will disconnect one motor from the line
and connect the frequency relays to the power resistors of the
other motor. The brakes of the motor not in service are still
released electrically.
FORM G95 lists a 3 square miniature voltmeter to monitor one
phase of motor primary voltage.
FORM G9 lists a 3 square miniature ammeter to monitor one
phase of motor primary current. Current transformers
form are supplied Form G9 for motors above 10 HP
20 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 DATA
CLASS 6420 EDDYMAG
DYNAMIC MODEL AB-
MOTOR HP
RATING
Brake Size
900 RMP Motors
Light Duty
Services
Severe
Duty
Services
7 1/2 703
10 704
15 704
20 705
25 705
30 705
40 706
50 706
60 706
75 707
100 707
125 707
150 707
200 708
250 708
300 708
ORDERING INFORMATION REQUIRED:
5. Motor Secondary Rated Voltage and
Current
6. Controller Modifications: Specify Form
Numbers
7. Resistors Services Classification
8. Master Switch Type and Form Number
AC CRANE CONTROL
23
CLASS
o42
CLASS
o42
o42
o422
o42o
CONTROLLER MODIFICATIONS
Standard controllers come equipped with the components listed.
Special features to be added to standard controllers are identified
by Form number. Most modifications are self explanatory.
list motor isolation circuit breakers for use on duplex
controllers. For operation of the drive on one motor, the motor
line and connect breakers will disconnect one motor from the line
and connect the frequency relays to the power resistors of the
motor. The brakes of the motor not in service are still
lists a 3 square miniature voltmeter to monitor one
lists a 3 square miniature ammeter to monitor one
Current transformers with this
for motors above 10 HP, 230 volt, and
PPLICATION DATA
CLASS 6420 EDDYMAG
@
HOIST
-FLOOR MOUNTED BRAKE*
1200 RMP Motors
Severe
Duty
Services
Light Duty
Services
Severe
Duty
Services
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
708 707 707
708 707 708
708 708 708
--- 708 708
7. Resistors Services Classification
8. Master Switch Type and Form Number
FRONTLINE
24
CLASS
o42
CLASS
o42
o42
o422
o42o
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%
H
O
O
K
S
P
E
E
D
I
N
%
O
F
S
Y
N
C
H
R
O
N
O
U
S
S
P
E
E
D
-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%
H
O
O
K
S
P
E
E
D
I
N
%
S
Y
N
C
H
R
O
N
O
U
S
S
P
P
E
D
FRONTLINE

AC CRANE CONTROL
APPLICATION DATA
CRANE HOOK SPEED VS LOAD PERFORMANCE
CLASS 6420 EDDYMAG

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
THIRD
FOURTH
FIFTH
FIRST
FIRST
SECOND & 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 SPEED
CLASS 6422 CONTRA
CLASS 6426
SECOND
FIRST
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%
H
O
O
K
S
P
E
E
D
I
N
%
O
F
S
Y
N
C
H
R
O
N
O
U
S
S
P
E
E
D
FIRST
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0% 20% 40%
H
O
O
K
S
P
E
E
D
I
N
%
S
Y
N
C
H
R
O
N
O
U
S
S
P
E
E
D
FRONTLINE

AC CRANE CONTROL
APPLICATION DATA
CRANE HOOK SPEED VS. LOAD PERFORMANCE
CLASS 6422 CONTRA-TORQUE

CLASS 6426 REVERSING HOIST CONTROL

(With Mechanical Load Brake)
FIFTH
AUTOMATIC
FOURTH
THIRD
FIRST & 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
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CLASS
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o42
o422
o42o
FIFTH
AUTOMATIC
FIRST & SECOND
180% 200%
180% 200%
FRONTLINE
26
CLASS
o42
AC CONTACTOR CONTROL
System AC Contactor Control
Crane Components
Wound rotor motor, rectifier operated
brake(s), control circuit and / or power limit
switches, master switch,
radio control.
Reversing hoists
mechanical load brake gearbox.
All other hoist styles
gearbox. Best and critical positioning control
requires E
Resistors
Acceleration resistor set
Size based on HP & duty cycle.
M
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P
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General
Velocity and acceleration is load dependant.
Resistor tap and wiring changes are required
to adjust speeds in the field.
More abrupt speed point
Slowdown
Travel: Slowdown via Reverse Plugging
deceleration, relay controlled, with resistors
to limit current and torque.
Hoist: OFF point slowdown and braking with
Eddy-Current brake,
DB circuitry
OFF Point
Travel: No OFF point braking via control
Hoist: OFF point braking by Eddy
brake, CONTRA
Reversing
Travel: Reversing plugging deceleration,
relay controlled, with resistors to limit current
and torque. Allows
operation.
Hoist: Drive is stopped before each change
in direction
Power Consumption
Power dissipated in rotor resistors in
speed points
Component Wear
Acceleration contactors make & break rotor
current at each speed change.
Directional contactors make & break stator
current when starting & reversing.
Contactors, tips, coils, etc. require periodic
inspection and replacement
Motors / Encoders
Requires wound rotor motor.
No encoder feedback
Motor blower not typically required
operation at reduced motor velocity, as full
torque is not available at zero speed

FRONTLINE

AC CRANE CONTROL
AC CONTACTOR CONTROL vs. DRIVES
AC Contactor Control Variable Frequency Drive
Wound rotor motor, rectifier operated
brake(s), control circuit and / or power limit
switches, master switch, and pendant or
radio control.
Reversing hoists require worm gear or
mechanical load brake gearbox.
hoist styles require standard
gearbox. Best and critical positioning control
es Eddy-Current load brake
Inverter-duty squirrel cage, wound rotor, or standard duty
squirrel cage motor, rectifier operated brake(s), control
circuit and / or power limit
pendant or radio control.
Open loop hoist controls require worm gear or
mechanical load brake gearbox.
Closed loop hoist controls
with motor encoder feedback.
Acceleration resistor set required,
Size based on HP & duty cycle.
Dynamic braking resistor set only, sized based on
inverter size, fewer resistor banks required.
Velocity and acceleration is load dependant.
Velocity and acceleration are minimally (open
(closed loop) load dependant.
Resistor tap and wiring changes are required
to adjust speeds in the field.
Velocity & acceleration are programmed for each speed
point, field adjustable through keypad or PC
More abrupt speed point transitions. Smooth speed point transitions.
: Slowdown via Reverse Plugging
deceleration, relay controlled, with resistors
to limit current and torque.
: OFF point slowdown and braking with
urrent brake, CONTRA-TORQUE or
DB circuitry
Slowdown via DB resistors on DC bus, with
programmable deceleration ramp
: No OFF point braking via control
: OFF point braking by Eddy-Current
CONTRA-TORQUE or DB circuitry
OFF point Dynamic Braking (DB),
deceleration ramp between all points, with load floating
to resume motion without waiting for brake to release
: Reversing plugging deceleration,
relay controlled, with resistors to limit current
and torque. Allows reacceleration after relay
operation.
: Drive is stopped before each change
in direction
Slowdown with DB (see Slowdown & OFF).
Reversing and reacceleration occur after zero speed
achieved.
Power dissipated in rotor resistors in low
speed points
Uses less power at reduced velocity, and during
acceleration
Acceleration contactors make & break rotor
current at each speed change.
Directional contactors make & break stator
current when starting & reversing.
Contactors, tips, coils, etc. require periodic
inspection and replacement
Power contactors eliminated.
Motor current switched by solid
Spare drive recommended.
Requires wound rotor motor.
No encoder feedback required
Inverter-duty squirrel cage motor preferred. Load filter
required for use with wound rotor or standard duty
squirrel cage motors. AIST Hoists (closed loop) use
motor encoder feedback for precise handling,
Motor blower not typically required for
operation at reduced motor velocity, as full
torque is not available at zero speed
Full torque (full current) at slow and zero velocity is
possible. As a result, motor blower may be required
when operating at reduced velocity with full load and high
duty cycles.
September, 2008
Frequency Drive
duty squirrel cage, wound rotor, or standard duty
squirrel cage motor, rectifier operated brake(s), control
circuit and / or power limit switches, master switch,
require worm gear or
mechanical load brake gearbox.
require standard gearbox, but
with motor encoder feedback.
Dynamic braking resistor set only, sized based on
inverter size, fewer resistor banks required.
Velocity and acceleration are minimally (open loop) or not
(closed loop) load dependant.
Velocity & acceleration are programmed for each speed
point, field adjustable through keypad or PC
Smooth speed point transitions.
Slowdown via DB resistors on DC bus, with
programmable deceleration ramp
OFF point Dynamic Braking (DB), with programmable
deceleration ramp between all points, with load floating
to resume motion without waiting for brake to release
Slowdown with DB (see Slowdown & OFF).
Reversing and reacceleration occur after zero speed
Uses less power at reduced velocity, and during
Power contactors eliminated.
Motor current switched by solid-state components.
Spare drive recommended.
duty squirrel cage motor preferred. Load filter
required for use with wound rotor or standard duty
squirrel cage motors. AIST Hoists (closed loop) use
motor encoder feedback for precise handling,
Full torque (full current) at slow and zero velocity is
possible. As a result, motor blower may be required
when 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 8 to 30 wheel diameters
Torque ratings 100 through 9000 ft-lbs
Corrosion resistant pins are standard on all brake sizes
Grease fittings are standard on 19, 23 and 30 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 10, 13, and 16 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 Brake,
and 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-ARC

contactors, static timers

Industrial duty contactor versions available to meet NEMA Service Classification II
CLASS 6440 AC MANUAL MAGNETIC DISCONNECT SWITCHES
Meet OSHA& NEC requirements for AC
Available in continuous ratings of 150 to 1350 Amperes
Operated remotely by pushbutton or by
Mechanical & electrical interlocks prevent switch
CLASS 6170 YOUNGSTOWN

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 Guide
For more details, please see our crane control catalog, on
Please visit our website for additional details on:
DC MILL DUTY CONTACTOR CONTROL, DIGITAL DC DRIVES,
DC DISCONNECT SWITCHES, DC MAGNET CONTROL, DC REDUCED VOLTAGE STARTERS,
MASTER SWITCHES, MILL DUTY RELAYS, OVERLOAD RELAYS, AC CONTACTORS,
AND OTHER
FRONTLINE

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 19, 23 and 30 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 10, 13, and 16 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-TORQUE, 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 & 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 Guide
For more details, please see our crane control catalog, on-line at www.ECandM.net
Please visit our website for additional details on:
DC MILL DUTY CONTACTOR CONTROL, DIGITAL DC DRIVES,
DC DISCONNECT SWITCHES, DC MAGNET CONTROL, DC REDUCED VOLTAGE STARTERS,
MASTER SWITCHES, MILL DUTY RELAYS, OVERLOAD RELAYS, AC CONTACTORS,
AND OTHER MILL DUTY CONTROL COMPONENTS
27
CLASS
o42
Available auxiliary contacts set to operate prior to main contacts, for variable frequency hoist applications
DC DISCONNECT SWITCHES, DC MAGNET CONTROL, DC REDUCED VOLTAGE STARTERS,
MASTER SWITCHES, MILL DUTY RELAYS, OVERLOAD RELAYS, AC CONTACTORS,
FRONTLINE
28
CLASS
o42
FRONTLINE

AC CRANE CONTROL
SEE SEPARATE PRICE SHEET OR CONTACT
EC&M FOR PRICE AND LEAD-TIME AT
WWW.ECandM.NET OR CALL 803-874
Copyright The Electric Controller and Manufacturing Company, LLC.
Printed in the USA
SEE SEPARATE PRICE SHEET OR CONTACT
EC&M FOR PRICE AND LEAD-TIME AT
WWW.ECandM.NET OR CALL 803-874
September, 2008
SEE SEPARATE PRICE SHEET OR CONTACT
TIME AT
874-3922
Copyright The Electric Controller and Manufacturing Company, LLC. 2007
SEE SEPARATE PRICE SHEET OR CONTACT
TIME AT
874-3922