How to debug the overload protection device of R137-24-45KW reducer
The debugging steps for the R137-24-45KW gearbox overload protection device are as follows:1、 Preparation before debugging
Cut off the main power supply of the equipment, hang a warning sign, conduct a power check to confirm that there is no power, and ensure safe debugging.
Check the rated current on the motor nameplate (the rated current of a 45KW motor is about 85A, subject to the actual nameplate), the rated output torque of the reducer, and the starting time.
Check that the lubrication of the reducer is normal, the oil level meets the standard, there is no jamming or abnormal noise, and the coaxiality is qualified.
Check that the electrical circuit wiring is correct, and that the normally closed contacts of the thermal relay/overload protector are connected in series to the control circuit.
2、 Debugging of thermal relay overload protection
Current setting: Adjust the setting current of the thermal relay to 1.05 times the rated current of the motor. For stable loads, it can be set to 1.05~1.1 times, and for impulse loads, it should not exceed 1.2 times.
Protection feature selection: Select CLASS10 for startup time ≤ 6 seconds, and CLASS20 for startup time ≤ 20 seconds.
No load test: Power on and run without load for 5-10 minutes, use a clamp meter to measure the balance of three-phase current, there is no missing phase, and the thermal relay does not operate.
Simulation test: Press the test button, and the contactor should immediately trip to verify the effectiveness of the protection circuit.
Load debugging: gradually load to rated load, run for 10-15 minutes, and the equipment will not trip normally; At 1.2 times the rated current, it should operate within the specified time.
Reset setting: Set to manual reset, and can only be reset and started after troubleshooting.
3、 Debugging of frequency converter/electronic overload protector
Set parameters such as rated current, rated power, and rated frequency of the motor.
The overload protection threshold is set to 1.05~1.1 times the rated current, with an action time of 60~120 seconds.
Enable phase loss, overcurrent, and stall protection, with an action time of 2 seconds.
Self learning with motor, optimizing protection curve to avoid accidental tripping during startup.
Test step by step with and without load to confirm reliable protection action.
4、 Mechanical torque limiter debugging (optional)
Set the trigger torque to 1.2~1.3 times the rated torque of the gearbox.
Adjust the pre tightening nut evenly and calibrate it with a torque wrench to ensure that it slips or trips when overloaded.
Ensure that mechanical protection and electrical protection are linked during testing, with mechanical protection acting first and electrical protection following.
After adjusting, tighten the nut and mark it properly to prevent loosening.
5、 Confirm after debugging
No load, rated load, and simulated overload can all respond normally without refusal or misoperation.
Record the tuning parameters, action time, and test results to form a debugging record.
Confirm that the operating temperature, vibration, and current of the equipment are normal before putting it into use.
