Some standard content:
Mechanical Industry Standard of the People's Republic of China
JB/T6748-93
This standard adopts the relevant provisions of IEC439 "Low Voltage Complete Switchgear and Control Equipment". 1 Subject Content and Scope of Application
This standard specifies the product classification, technical requirements, test methods, inspection rules and markings, packaging and transportation of crane control consoles. This standard applies to crane control consoles installed in the driver's cab (hereinafter referred to as control consoles). The control console is used in the main circuit and control circuit of AC 50Hz (or 60Hz) and rated voltage 660V and below, and can also be used in the control circuit of DC rated voltage 440V and below to control the starting, speed regulation, braking and reversing of the motor of the lifting and transportation machinery. 2 Reference standards
Colors of indicator lights and buttons in electrical complete sets GB2682
GB2900.18 Electrical terminology Low-voltage electrical appliances GB4205
GB4720
GB10233
Standards for operating parts of electrical equipment Direction of movement Electrical control equipment Part 1 Low-voltage electrical appliances Electrical control equipment Basic test methods for electrical transmission control equipment GB14048.1
JB3084
General principles for low-voltage switchgear and controlgear
Low-voltage motor starters Part 1 Direct current (full voltage) starter Low voltage motor starter Part 3 Product packaging and transportation regulations for rotor rheostatic starter power transmission control station JB4013.1
JB4315
General requirements for control circuit electrical appliances and switch elements Crane electric control equipment
JB/DQ56027
Product quality classification of crane electric control equipment
3 Terms and terms
3.1 Except for the terms specified in this standard, the rest shall comply with the terms specified in GB2900.18, GB4720 and JB4315. 3.2 Special terms in this standard:
Crane control console - a control console equipped with one or more controllers and other electrical components for controlling cranes, one of which a.
Operating handle can control one or two controllers; b. Special controller: a controller designed and manufactured specifically for crane control consoles, which cannot be an independent product; c.
Universal controller: a standardized controller product that is installed in a crane control console after removing the outer shell and handle (or handwheel). 4 Product classification and model
4.1 Product classification
According to the combination of controllers, it is divided into
Full master control console;
Full cam control console;
Approved by the Ministry of Machinery Industry of the People's Republic of China on 1993-08-21 and implemented on 1993-10-01
JB/T6748-93
Hybrid control console (the control console is equipped with both a master controller and a cam controller). 4.1.2 According to the number of controllers, it is divided into
One controller control console;
Two controller control console;
Three controller control console;
Four controller control console;
Five controller control console;
Six controller control console.
4.2 Product model
The model of the control console and its meaning are as follows:
口O口
-Line scheme number (expressed in numbers)
63(60)A Number of cam controllers
-25A or 32A Number of cam controllers
5A or 10A Number of master controllers
Variety code!
Series design serial number (number, starting from 1) Series feature code (T: control console)
Category code (Q: crane)
Note: 1》Variety code, the following letters are used to indicate the type of crane to which the control console is applicable; D: For hoist single-beam crane:
J: For tower crane for construction;
M: For portal crane For heavy machinery:
P; For general bridge cranes, gantry cranes, loading and unloading bridges; S: For Yinlu Shuangsang cranes:
X: For container cranes:
Z: For special cranes,
5 Technical requirements
5.1 Environmental conditions
5.1.1 Normal working conditions
The console should be able to work normally under the following conditions: a.
The altitude shall not exceed 2000m;
The ambient air temperature shall not exceed +40°C, and the average temperature within a 24h period shall not exceed +35°C. The ambient air temperature shall not be lower than the clean air. At the maximum temperature of +40°C, the relative humidity shall not exceed 50%, and the relative humidity may be increased at a lower temperature (for example, 90% at 20°C). However, it should be considered that due to temperature changes, slight condensation may occur occasionally: d.
The power supply network is of qualified quality, and the fluctuation range of the incoming voltage does not exceed ±10% of the rated voltage value: vertical installation, the inclination does not exceed 5°;
The installation is firm, and there will be no horizontal movement and vertical jump relative to the host during the operation of the host; the maximum vibration condition of the installation part is: 5-13Hz, the displacement is 1.5mm: 13150Hz, the vibration acceleration is 10m/s.
5.1.2 Transportation and storage conditions
JB/T6748-93
During transportation and storage, the temperature condition of the console can be relaxed to -25~+55C, and the temperature can reach +70 C for a short time (not more than 24h).
5.1.3When the above conditions are exceeded, the user and the manufacturer shall sign a special agreement. 5.2 Structure, seat and operating mechanism
5.2.1 Structure and seat
5.2.1.1 The shell of the console should be made of materials that can withstand certain mechanical, electrical and thermal stresses, and can withstand the influence of moisture that may be encountered under normal use conditions.
5.2.1.2 The shell protection level of the console should not be lower than IP30. 5.2.1.3 The structure of the console should ensure safety and reliability during commissioning, operation, maintenance and inspection. At the same time, the heat, arc, impact, vibration, magnetic field or electric field generated by each electrical component during operation shall not affect the normal function of other electrical components, or even cause malfunction.
The structural dimension deviation of the console shall comply with the provisions of Table 1, Table 2 and Table 3 in JB/DQ56027 "Quality Classification of Crane Electric Control Equipment Products".
5.2.1.5 The structural welding of the console should be firm, and the weld should be smooth and uniform, without obvious deformation and defects such as welding penetration, cracks, arc pits, and weld nodules. 5.2.1.6 The edges of the parts and openings of the control console should be smooth and flat, without obvious burrs and cracks. 5.2.1.7 The inside of the control console must be welded with a grounding screw (or nut) of not less than M6, and the welding must be firm. It is prohibited to spray an insulating coating on the threads and conductive contact surfaces, but anti-rust measures should be taken in this area. 5.2.1.8 The metal structure and supporting parts of the control console should generally be sprayed with a non-glaring and reflective coating. The coating should be firmly attached, the color should be uniform, the surface should be neat and beautiful, and there should be no defects such as wrinkles, flow marks, pinholes, and bubbles. 5.2.1.9 The seat of the control console should be firm, durable, comfortable and spacious. The seat should be easily adjusted in both the front and rear and height directions, and must be firmly locked and fixed after adjustment; the seat back should have a certain variable inclination. The seat design should facilitate the driver to enter the operating position from the rear. The platform body and the seat of the rotary control console equipped with control equipment should be relatively fixed and rotate flexibly together. The rotation of the control console should be equipped with limit devices and stop devices. 5.2.2 Operating mechanism
5.2.2.1 The operating mechanism should be solid and firm and can only be disassembled with tools. The operating mechanism should have sufficient mechanical strength to withstand the strength test specified in Article 6.10.
5.2.2.2 The operating handle of the control console should be guaranteed not to leave the zero position easily due to vibration and accidental contact with the surface. It can be equipped with a zero position locking mechanism or take other measures to prevent misoperation; when operating the handle, the gear position should be clear and can accurately stay at the specified gear position; when the handle returns to the zero position, it should be accurate and reliable. The swing angle of the handle caused by the neutral gap in each gear (hereinafter referred to as the neutral swing angle) should not be greater than 5°. 5.2.2.3 There should be good insulation between the operating mechanism and the live parts to ensure safety. If the operating mechanism is made of metal, it should be connected to the protective grounding conductor, otherwise additional insulation measures should be taken. 5.2.2.4 The movement direction of the operating handle shall comply with the provisions of GB4205. 5.2.2.5 The operating handle on the control console should be set in front of the driver and should be arranged in the position where the human hand is most sensitive, has the best discrimination and the fastest response. The height of the upright operating handle should be within the range of 700-900mm. The movement space of the operating handle during operation should generally meet the requirements of the normal working range of the human hand, and the control console with multiple mechanisms should not exceed the requirements of the maximum working range of the human hand [see Appendix A (Supplement).
5.2.2.6 The layout and movement direction of the operating handle used to control the various mechanisms of the crane on the control console should generally meet the provisions of Appendix B (Supplement) to reduce confusion and erroneous operation in emergency situations. In special cases, the manufacturer is allowed to arrange the operating handle according to the agreement with the user.
5.3 Selection, installation and wiring of electrical components 5.3.1 The electrical components installed in the control console should meet the requirements of their respective product standards. The rated voltage, rated current, service life, connection and disconnection capacity, short-circuit strength and vibration resistance of the components should meet the relevant requirements of this standard and product drawings. 5.3.2 For some components that cannot work properly on the crane but must be used, special measures (such as vibration reduction, ventilation, etc.) should be taken according to the specific situation to ensure their normal operation. JB/T6748--93
5.3.3 The special controllers and general controllers used in the control console shall comply with the requirements of GB14048.1. The master controller shall also comply with JB4013.1, and the cam controller shall also comply with the requirements of JB2458.1 and JB2458.3. At the same time, the test parameters of its connection and disconnection capacity and electrical life shall meet the requirements of the use category listed in Table 1. The basic use category of the cam controller is AC-2 (controlling winding motors); for cam controllers that control squirrel cage motors and use categories of AC-3 and AC-4, the manufacturer shall provide the rated working current (or control motor power) allowed by the controller under the corresponding use category in the control console product sample. Table 1
Agreed heating current of controller contacts
5, 10
25, 32, 63 (60)
Use category code
AC-15 DC-14
(AC-3.AC-4)
5.3.4 An emergency switch that can cut off the main power supply of the crane should be installed on the control console where the driver can quickly reach it. The emergency switch should be a manual reset switch or a mushroom head button. 5.3.5 The colors of the indicator lights and buttons used in the control console should comply with the provisions of GB2682. 5.3.6 The layout of the components on the control console should be neat and beautiful, and easy to operate and maintain. Various electrical components, accessories and parts must be firmly installed in accordance with relevant installation regulations and process codes, and should not be loosened, twisted, displaced or fall off due to the vibration during normal operation of the crane, which will affect the normal operation of the electrical components and the control console. 5.3.7 The electrical clearance between the electrical components on the control console and between them and the exposed conductive parts should be no less than 8mm, and the creepage distance should be no less than 14mm.
5.3.8 The connecting wires of the control console should be copper core multi-strand insulated soft wires. The cross-sectional area should generally be no less than 1.5mm\. For circuits with very small current (such as electronic circuits), the wire cross-sectional area should not be less than 0.5mm*. 5.3.9 The wiring of the control console should be correct, and the wiring should be neat and beautiful. The wires should not be close to exposed live parts with different potentials or objects with sharp edges. The wiring harness should have sufficient strength or reliable support. 5.3.10
When the wires are connected to the movable structural parts, they should be bundled and wrapped with non-self-igniting hoses. When the wire harness needs to be bent, its bending radius should be greater than 10 times the outer diameter of the wire harness. 5.3.11
Except the main circuit, the lead wires of other circuits should be connected to the terminal block in a centralized manner. 5.3.12
The ends of the wires connected to the terminal block and electrical components should have copper bare crimping terminals and should have permanent independent markings consistent with the circuit diagram (or wiring diagram).
5.4 Technical Performance Index
The rated insulation voltage of the control console is 660V. The controller's agreed thermal current is divided into five types: 5, 10, 25, 32 and 63 (60) A, of which 5 and 10A are for master controllers; 25, 325.4.2
and 63 (60) A are for cam controllers. In various specifications of cam controllers, the agreed thermal current of the auxiliary circuit contacts is 10A. 5.4.3 The controller is an intermittent cycle working system, and its basic load factor (power-on duration) is 40%. 5.4.4 The number of on-off operation cycles that the console operating mechanism can perform per hour is 1200 times (all master control console) and 600 times (all cam or mixed control console).
5.4.5The mechanical life of the console operating mechanism shall not be less than 3 million times. Note: The operation handle moves from the zero position to the terminal in one direction and then returns to the winter position once. 5.4.6The operating force of the console operating mechanism (when operating only one controller) shall not exceed the following provisions: a.
5, 10A master controller is 25N;
25A cam controller is 35N:
32A cam controller is 40N;
d.63(60)A cam controller is 50N.
JB/T6748-93
5.4.7The metal shell of the console or metal parts that may be charged (including metal parts that may be charged due to insulation damage) and the grounding screw must have a reliable electrical connection. The connection resistance between them shall not be greater than 0.1α. Note: The electrical connection between the table cover (door) equipped with electrical components and the metal body must be achieved with yellow-green two-color soft wire. 5.4.8 Before the dielectric test, the insulation resistance of each circuit in the control console shall be measured with a megohmmeter, and the value shall not be less than 1MQ. This data is only for reference during the dielectric test.
5.4.9 Each circuit of the control console (including directly connected measuring instruments) shall be able to withstand the specified level of AC sine wave dielectric test voltage for 1 minute without breakdown or flashover. The dielectric test voltage of the main circuit of the control console and the control circuit and auxiliary circuit allowed to be connected to the main circuit are shown in Table 2. The dielectric test voltage of the control circuit and auxiliary circuit that are not directly connected to the main circuit according to the design is shown in Table 3. Table 2
Rated insulation voltage U.
60U300
300≤660bZxz.net
Rated insulation voltage U
Dielectric test voltage (AC effective value)
Dielectric test voltage (AC effective value)
2U,+1000not less than 1500
When the controller is energized with the corresponding rated working current and the temperature rise stabilizes, the temperature rise of its wire connections, operating handles, housing and other parts shall not exceed the provisions of Table 4.
Electrical components of internal devices
Terminals connected to external insulated wiresCopper busbar joints
Contacts without anti-corrosion coating
Contacts tinned
Contacts silver or nickel plated
Operating handle
Made of metal
Made of insulating material
Touchable enclosure
Metal surface
Insulating surface
Comply with the standards of the respective electrical components
Note: 1) The temperature rise limit of 70K is formulated in accordance with the test conditions specified in 5.2.1.2 of JB4315. When the console is used and tested under actual installation conditions, different temperature rise limits are allowed due to the difference between the connection type, type and arrangement and the specified test conditions. 41
There are 600 readings left,
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JB/T674893
5.4.11 The control console should be able to withstand the vibration test specified in Article 6.15. After the test, its structural parts should not be loose, deformed or damaged; the operating handle should not deviate from the original gear position due to vibration, and the strength of the operating mechanism, the neutral swing angle of the handle in each gear position and the change of the operating force should not exceed the allowable range; the electrical components should be able to work normally without poor contact and malfunction, otherwise anti-vibration measures should be taken. 6 Test methods
6.1 Appearance inspection
After the console is manufactured, before other items are inspected, an appearance inspection should be carried out according to the product drawings and the requirements of Articles 5.2 and 5.3 of this standard. The main contents are:
Whether the structure selection, parts specifications and installation are correct; whether the selection, layout and installation of electrical components, and the specifications and layout of wires meet the requirements; whether the protection circuit meets the requirements, and whether its bolt connections are in reliable contact; whether the setting position, layout and movement direction of the operating handle and the color of the indicator lights and buttons meet the specified requirements; whether the operating mechanism is flexible and reliable, whether the gear position is clear when operating the handle, and whether the zero-position locking mechanism is effective; whether the accompanying materials and signs are complete and intact, and whether they are consistent with the product. 6.2
2 Verify electrical clearance and creepage distance
Electrical clearance and creepage distance should be verified and measured to confirm that they meet the requirements of Article 5.3.7. The possible deformation of structural parts should also be taken into account during measurement, including changes caused by short circuit. 6.3 Protection circuit continuity test
Measurement of the ground connection resistance of the control console by bridge method or DC voltage drop method should meet the requirements of Article 5.4.7. 6.4 Wiring check
Check whether the wiring of all electrical components is correct. For the controller, the handle should be placed in each gear, and the on-off state of each contact and the connection should be checked from the wiring terminal to see whether it meets the requirements of the drawing. 6.5 Insulation resistance test
Perform according to the method specified in "5.2.2.4 Insulation resistance measurement" in JB4315. 6.6 Dielectric property test
Perform according to the method specified in \5.2.1.6 Dielectric test\ in JB4315. However, during the factory inspection of the product, the test voltage only needs to be maintained for 1s.
6.7 Temperature rise test
Perform the method specified in *5.2.1.2 Temperature rise test\ of JB4315. 6.8 Shell protection level test
Perform the method specified in "17 Shell protection level test" of GB10233. 6.9 Handle neutral swing angle detection
Put the operating handle in each gear position. You can use the method of directly measuring the angle with a protractor or the method of measuring the displacement of the top of the handle and then converting it. The neutral swing angle of the handle should meet the requirements of Article 5.2.2.2. 6.10 Operating mechanism strength test
After pushing the operating handle to the terminal position in a certain direction, continue to slowly apply a force of 300N in the original operating direction and keep it for 1min. Check that all parts of the operating mechanism should be free of damage and can work normally to be qualified. The point of force applied is 25 to 30mm away from the top of the operating handle.
6.11 Mechanical life test of operating mechanism
Perform the test in accordance with the method specified in \8.2.3.7.1 Mechanical life test\ of GB14048.1. The total life times of the operating mechanism shall be evenly distributed in each movement direction of the handle. For hybrid control consoles or full cam control consoles, at least one 63(60)A cam controller shall be used for the test.
6.12 Operating force test of operating mechanism
JB/T674893
Measure with a force spring balance, with the force measuring point 2530mm from the top of the operating handle, and the force measuring direction consistent with the normal operating direction. The maximum operating force of each gear shall not exceed the value specified in Article 5.4.6. 6.13 Verification of the use category of general controllers or type inspection of special controllers a. When the console adopts a general controller, the verification test of the switching capacity and electrical life shall be carried out according to the use category specified in Article 5.3.3. The test shall be carried out according to the method specified in the controller product standard, but it must be assembled with the operating mechanism of the console for testing; b. When the console adopts a special controller, the test shall be carried out separately according to the type inspection items and test methods specified in the corresponding standards listed in Article 5.3.3. Among them, the switching capacity and electrical life tests shall be carried out together with the operating mechanism of the console according to the use category specified in Article 5.3.3; the remaining test items and methods can be combined if they are the same as the type inspection items and methods specified in this standard. 6.14 Ambient temperature test
When the electrical components used have passed the low temperature and high temperature tests during the type inspection, and the low temperature and high temperature values selected during the test are equal to or stricter than those specified in this standard, the ambient temperature test can be omitted. The ambient temperature test of the control console shall be carried out in accordance with the method specified in "5.2.1.3 Ambient temperature test" of JB4315. 6.15 Vibration resistance test
It shall be carried out in accordance with the method specified in "5.2.1.4 Vibration resistance test" of JB4315. 7
Inspection rules
Inspection classification
The inspection of the control console is divided into two categories: factory inspection and type inspection. 7.2
Type inspection
The purpose of type inspection of the control console is to verify whether the product meets the requirements of this product standard. Type inspection is carried out in the following circumstances:
After the trial production of new products is completed, the finalization appraisal is carried out;
When the finalized products are transferred to the factory for production;
After major design and process changes that may affect the basic performance of the product. Type inspection can be carried out on a representative product, or on several products manufactured according to the same (or similar) design. The test of each item can be carried out separately. Type inspection must be carried out on the basis of the qualified factory inspection of the product. 7.2.2
The type inspection items of the control console include:
All factory inspection items except 1$ dielectric test; protection circuit continuity test;
dielectric performance test:
temperature rise test;
shell protection grade test;
operating mechanism strength test;
operating mechanism mechanical life test;
operating mechanism operating force test;
general controller use category verification or special controller type inspection; environmental temperature test;
vibration resistance test.
If all the above test items are qualified, the product type inspection is qualified. If one item is unqualified, a one-time repair is allowed. If the repeated test 7.2.3
is qualified, it can be considered that the type inspection is qualified. If the repeated test is still unqualified, the product type inspection is judged to be unqualified. 7.3 Factory Inspection
7.3.1 Each console product must pass the factory inspection before it can leave the factory. The factory inspection items of the console include:
Appearance inspection;
Verification of electrical clearance and creepage distance;
Wiring inspection;
Insulation resistance test;
1s dielectric performance test;
Handle neutral swing angle detection;
Factory sampling test of special controllers.
JB/T674893
For consoles using special controllers, factory sampling tests are carried out on the controllers before leaving the factory. The items and methods of the sampling tests are specified by the manufacturer in its product standards or technical documents in accordance with the requirements of the corresponding controller product standards. Only when all the above test items are qualified can it be judged as qualified for factory inspection. 7.3.3
Marking, packaging and transportation
A product nameplate should be fixed on each console. The nameplate should have the following information: a.
Manufacturer name;
Product name;
Product model:
Rated working voltage;
Rated working current;
Weight, kg;
Factory number;
Date of manufacture.
Items d and e should be listed separately if they are inconsistent for each controller. If it is difficult to list them, they can be clearly marked on the obvious part of the controller.
8.2 The control console shall also have the following signs:
Signboards indicating the direction of movement of the crane mechanism shall be arranged near each operating handle of the control console; each controller shall be a.
equipped with a project code mark consistent with the wiring diagram; each controller must be accompanied by a closing table consistent with the actual closing sequence, fixed in the side cover on the inside of the control console; b.
Other components except the controller shall have name or functional word plates on the table top, and project code marks consistent with the wiring diagram shall be placed near the components on the back of the table;
The ends of the wires connected to the wiring wax and all components shall be marked with permanent marks consistent with the wiring diagram; there shall be an obvious grounding symbol next to the grounding screw of the control console. 8.3 Documents accompanying the product packaging:
Product certificate;
Product instruction manual;
Packing list (including random documents and random accessories). 8.4 The packaging and transportation of the control console shall comply with the provisions of JB3084. 44
Left-hand average operation drawing
Left-hand maximum question country
JB/T6748-93
Appendix A
Horizontal working range of human hands
(Supplement)
Difficult to set up normal operation operation drawing
Appendix B
Arrangement and movement direction of control console operating handles (Supplement)
Hand maximum secret
Right-hand average onion drawing
The arrangement of the control console operating handles with main and auxiliary lifting mechanisms is shown in Figure B1 (main and auxiliary lifting double handles) and Figure B2 (main and auxiliary lifting single-hand B1
handles).
Direction of trolley (truck) movement
Direction of trolley (truck) movement
Note: The height of the main lifting operating handle in Figure B1 should be lower than the height of the auxiliary lifting operating handle. Direction of sight
Direction of trolley (truck) movement
Direction of trolley (truck) movement
JB/T 6748-93
B2 For the arrangement of the control console operating handle without auxiliary lifting mechanism, see Figure B3. Forward
Direction of trolley (truck) movement
Direction of trolley (truck) movement
B3 For the arrangement of the control console operating handle with grab mechanism, see Figure B4 or Figure B5. Two front
Direction of movement of trolley (big car)
Direction of movement of trolley (small car)
Direction of sight
Direction of sight
Direction of sight
Note: The two operating handles controlling the grab mechanism in Figure B4 should be able to move separately and jointly forward
Direction of movement of trolley (train)
Direction of movement of trolley (small car)
Direction of sight
Note: In Figures B1 to B5, the arrow direction is the direction of movement of the operating handle, and the direction marked with text is the direction of movement of the mechanism46
Additional instructions:
JB/T674893
This standard is proposed and managed by Shenyang Electric Drive Research Institute. This standard is drafted by Tianshui Great Wall Control Electric Appliance Factory. Zhejiang Yiwu Electric Factory, Dalian Switch Factory, Shanghai Hoisting Electric Factory, Hunan Xidu Electric Factory, Shandong Hualu Low Voltage Switch Factory, Suzhou Electric Control Equipment Factory, Tianjin Second Hoisting Electric Factory participated in the drafting. The main drafter of this standard is Zhao Guosang.
Participating drafters of this standard are Ma Gongsi, Zhang Qin, Yang Junyi, Huang Bin, Li Chenglin, Zhong Qingchun, Qian Jin, and Li Baozhong. From the date of implementation of this standard, the original JB/DQ6146-86 "Crane Control Panel" will be invalid.
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