EN21004243A Roller Stations

Machine manual

en-21004.243-A

POLROr

self−aligning roller station

for mechanical direct drive

(2 roller drive)

Code word

Order No.

AAT items

Machine manual

POLROr self−aligning roller station for mechanical direct drive (2 roller drive)

Contents

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Contents

1 Technical data 1−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 Safety 2−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 Components and mode of functioning 3−1 . . . . . . . . . . . . . . . . . . . . . 3.1 Components 3−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Mode of functioning 3−18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 Transport and assembly 4−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 Transport and storage instructions 4−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Assembly 4−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 Lubrication 5−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 Preparation for test run 6−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1 Checks prior to the test run 6−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2 Setting and adjustment 6−2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 Maintenance 7−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Servicing 7−2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Trouble shooting 7−2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Repair 7−4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 Spare parts 8−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 Appendix 9−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1 Technical drawings 9−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 Subsuppliers’ documentation 9−1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine manual

POLROr self−aligning roller station for mechanical direct drive (2 roller drive) 1−1

Technical data

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1 Technical data

NOTEInformation concerning the electrical equipment is contained in the separateelectrical documentation or in the subsuppliers’ documentation.

Specification of the intended use

see machine manual of the rotary kiln No.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Basic data

Year of manufacture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Station “I“

AAT item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of the ollers mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width of the rollers mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of the bearing mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total clearance between thrust discs and thrust ring mm. . . . . . . . . . . . . . . . . . . . .

Gap ”s” at the set screws mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight of the roller with axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature sensor (optional extra) yes/no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type PT 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter 8 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation length (L + L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine manual

POLROr self−aligning roller station for mechanical direct drive (2 roller drive)1−2

Technical data

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Station ”II“

AAT item . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of the rollers mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width of the rollers mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of the bearing mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total clearance between thrust discs and thrust ring mm. . . . . . . . . . . . . . . . . . . . .

Gap ”s” at the set screws mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight of the roller with axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature sensor (optional extra) yes/no. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type PT 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter 8 mm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation length (L + L1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil circulation lubricating system

Quantity 1 pump per bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type of oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Machine manual


Safety

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2 Safety

NOTEBe sure to comply with the general safety instructions in the supplement Importantnotes on the documentation.

Use

D The supporting roller station is a component of the rotary kiln.Be sure to comply with the specification of the intended use in section Technicaldata.

D Any use other than the intended use is forbidden. POLYSIUS AG is notresponsible for damage resulting from any use other than the intended use. Allother use is at the owner’s own risk.

D The intended use also includes the observance of the instructions in the machinemanual and the compliance with the maintenance instructions.

Transport and assembly

D All transportation instructions in this machine manual refer exclusively totransportation of the machine at the plant site.

D Only use suitable hoisting and lifting equipment which is in serviceable order andhas a sufficient load bearing capacity.

D Never work under a suspended load.

Operation

D Any safety checks before or during operation depend on the relevant nationalregulations. The plant management is responsible for the performance andrecording of such checks.

D If changes in the machine or its operating behaviour relevant to safety occur, shutit down immediately.

Machine manual


Safety

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Maintenance

D Ensure that all machines and motors whose operation might endanger personsor equipment are switched off and safeguarded against restarting for the entireduration of the maintenance work.

D Ensure that all rotating parts of the machine have come to a complete standstillbefore you remove any protection devices or open any flaps.

D Before performing any work on the machine, make sure there is no risk of burnswhen touching the machine.

D After opening the top cover of the bearing, do not insert fingers or hands into thebearing: danger of crushing or tearing off due to rotating oil scoops.

D Keep the machine free of oily and combustible substances and materials. Neveruse gasoline or other easily inflammable substances for cleaning the machine.

D Switch off the power supply to the electrical components before commencing anymaintenance work.

D The plant management has to ensure that the whole area of the rotary kiln iscordoned off, so that it is impossible for persons to come into contact with rotatingparts.

D It is forbidden to carry out work at the rotating kiln.

D Before beginning any repair work, make absolutely sure that the rotary kiln hasswung to a complete stop in its centre of gravity position and has been securedby means of the holding brake!

D Strictly observe the welding instructions when performing any welding work.

D If you carry out electrical welding on any part of the machine, never conduct thewelding current through plain or antifriction bearings, other movable connectionsor measuring devices. Always directly connect the welding current return lead tothe part being welded.

D Remount all protection devices when maintenance work has been finished. Makeabsolutely sure that no persons are inside the plant component before youproperly close the inspection and service covers.

Machine manual


Components and mode of functioning

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3 Components and mode of functioning

The rotary kiln is supported on the supporting roller stations “I“ and “II“ of the twotyres; the occurring forces are transmitted into the foundations.

The roller stations are mounted on self−aligning bedplates that are fixed onto thefoundations.

The rollers of supporting roller station “I“ are directly driven via the adapters.

3.1 Components

NOTESome details of the drawings in this manual may not be identical with the drawingssupplied under the contract as listed in section 9.1 Technical drawings.

Each supporting roller station essentially consists of the following components:

D the self−aligning bed plate units

D the tyre saddle

D the rollers

D the supporting roller bearings

D the adapters for receiving the direct drive

D the direct drive (see separate machine manual)

D the protection devices

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The self−aligning supporting roller stations consist of the following subassemblies:

1.0 Supporting roller with axle

2.1 Supporting roller bearings for roller station “I“

2.2 Supporting roller bearings for roller station “II“

2.40 Temperature sensor (optional extra)

3.0.1 Self−aligning bed plate unit for roller station “I“

3.0.2 Self−aligning bed plate unit for roller station “II“

4.0 Drive

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Figure 1

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Roller station “I“

Items shown in the drawing of the self−aligning bed plate unit (3.0.1)

3.1.1 Bedplate ”I”

3.2 Bedplate ”II”

3.3 Bedplate “III“

3.4 Bedplate “IV“

3.5 Central bed plate

3.8 Bedplate anchorage

3.10 Elastomer bearing for motion absorption

3.11 Adjusting spindle with position sensor


1.1 Graphite block lubrication

4.0 Drive

7.0 Stabiliser

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Figure 2

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3.11 Adjusting spindle

3.14 Set screws


2.1 Supporting roller bearing for roller station “I“

2.40 Temperature sensor (optional extra)

6.0 Balance weight

7.0 Stabiliser

NOTEThe dimension of the gap ”s” at the set screws is described in section Technical data.

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Figure 3

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3.6 Tyre saddle

3.7 Tension rod



3.12 Distance sensor, tyre

3.13 Distance sensor, roller


4.0 Drive

5.0 Radiant heat protection

6.0 Balance weight

7.0 Stabiliser

Figure 4

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Figure 5

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Items shown in the drawing of the supporting roller bearing (2.1) for roller station “I“

2.3 Bearing housing

2.4 Bearing bush

2.5 Half thrust ring

2.6 Oil scoop

2.7 Inspection cover


2.9 Venting connection

2.10 Splash ring

2.11 Centering ring

2.11.1 Tensioning screw for the centering ring

2.11.2 Guide strip

2.12 O−ring

2.13 Stuffing box gland

2.13.1 Tensioning screw for the stuffing box gland

2.13.2 Packing

2.13.3 Scraper ring

2.14 Lubricant inspection glass

2.15 Oil pump

2.16 Bearing cover

2.17 Centering ring


2.17.2 Guide strip

2.18 O−ring



2.19.2 Packing

2.19.3 Scraper ring

2.20 Transverse key

2.21 Adapter for receiving the drive motors

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Figure 6

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Roller station “II“

items shown in the drawing of the self−aligning bed plate unit (3.0.2)

3.1.2 Bedplate ”I”

3.2 Bedplate ”II”

3.3 Bedplate “III“

3.4 Bedplate “IV“

3.5 Central bed plate

3.6 Tyre saddle

3.7 Tension rod

3.8 Bedplate anchorage



1.1 Graphite block lubrication

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Figure 7

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Roller station “II“

items shown in the drawing of the self−aligning bed plate unit (3.0.2)

3.6 Tyre saddle

3.11 Adjusting spindle with position sensor

3.13 Distance sensor, roller


NOTEThe dimension of the gap ”s” at the set screws is described in section Technical data.

Figure 8

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Figure 9

Figure 10

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Items shown in the drawing of the supporting roller bearing (2.2) for roller station “II“

2.3 Bearing housing

2.4 Bearing bush

2.5 Half thrust ring

2.6 Oil scoop



2.9 Venting connection

2.10 Splash ring

2.11 Centering ring


2.11.2 Guide strip

2.12 O−ring



2.13.2 Packing

2.13.3 Scraper ring

2.14 Lubricant inspection glass

2.15 Oil pump

2.30 Bearing cover

2.31 Thrust disc

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Figure 11

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3.2 Mode of functioningFor supporting the rotary kiln, each roller station requires two rollers with one pairof bearings each, plus the associated bed plate units.As a rule, the rollers are so arranged that the connecting lines from the centre of theroller to the centre of the tyre form an isosceles triangle with an apex angle of 60°.The forces caused by the supported load are received by the roller stations andtransferred into the foundation.The dimensions of the kiln tyre and the supporting rollers, as well as those of all rollerstation components are selected to suit the expected operating conditions of therespective rotary kiln.To ensure a good contact pattern and avoid impermissibly high local Hertzianpressures between a wobbling tyre and the supporting rollers, the rollers have aself–aligning supporting system.In combination with a direct drive system, the rollers also transmit the driving torqueto the kiln tyre. The drive acts on one or two rollers of one station.

Supporting rollers and axlesThe cast or forged solid section rollers are non–detachably connected to the forgedsupporting roller axles and have drill holes for transportation purposes.The axle ends have been prepared for receiving the adapter of the direct drivesystem.

Supporting−roller bearingsThe bearings consist of a cast housing with integrated coolant compartments andof the bearing bush halves and the collar ring halves made of a special bearing metalwith very good emergency running characteristics.The supporting–roller bearings are so designed that PT 100 temperature sensorscan be installed.The axle ends are mounted in the bearing bushes. Axial forces are transmitted viathe thrust rings bolted onto the axle to the collar of the bearing bushes and the halfthrust rings.The plain bearings are lubricated with mineral oil (see section Lubrication). Oilscoops mounted on the axle take oil from the sump and pour it onto the upper(free)area of the shaft journal.The lubricant enters through a wedge–shaped inlet gap on the inward–turning sideof the bearing bush, is distributed over the entire length of the bearing bush andpasses into the lubrication gap.This type of bearing and lubrication provides high operating reliability.Specially for the starting phase of the rotary kiln and operation with low rotationspeeds, the supporting–roller bearings are equipped with oil pumps. It is wise toobserve a prelubrication period of approx. 2–5 minutes before starting to turn the kiln.However, for safety reasons the lubrication during operation is performed by the oilscoops.The coolant for the supporting–roller bearings (generally cooling water) flowsthrough cooling compartments in the bearing base.In order to correct the position of the rotary kiln, you can shift the supporting–rollerbearings (and thus the rollers) transverse to the rotary kiln axis by using the bearingpositioning units.

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You can perform this adjustment under operating load, as the bearing positioningunits are designed to accept a hydraulic bearing adjustment device. You have toadjust both bearings of one supporting–roller simultaneously in steps of approx.0.2mm. Check this by means of a dial gauge.

After relieving the spindle by means of the hydraulic press, perform the adjustmentas described above. Then remove the hydraulic press.

When readjusting the supporting–roller bearings pay attention that no impermissibleheating up of the thrust disks and collar rings occurs, as this is a sign of skewing ofthe supporting roller axis relative to the rotary kiln axis, which can causeimpermissibly high axial forces.

The supporting–roller bearings are axially secured by lateral sliders.

Special seals are installed in the shaft passages to prevent oil losses.

Elastomer bearings for motion absorption

The elastomer bearings for motion absorption are made of special materials suitedto the rotary kiln operation and are pressure−resistant and thrust−resilient. Thesebearings permit deflection in the case of a wobbling kiln tyre in spite of greatoperating loads.

The elastomer bearings for motion absorption must be protected against oils,greases, chemicals etc. as this considerably reduces serviceability.

Self−aligning bed plate unit

The pair of bearings belonging to each supporting roller is movably mounted on thebedplates ”I” (3.1.1 and 3.1.2) and is only secured by the bearing positioning units.This provides the possibility to preset the supporting–roller bearing relative to therotary kiln axis.

The spreading forces are transmitted via the tension rods (3.7) and the central bedplate (3.5).

At supporting roller stations ”I“ and ”II“, the bedplates ”I“ (3.1.1 and 3.1.2) aremovable via an elastomer bearing for motion absorption (3.9) relative to bedplate “II“(3.2). This permits in combination with the adjusting spindle (3.11) fine alignment ofthe supporting roller relative to the rotary kiln axis during normal kiln operation.

Self−alignment of the supporting roller station is ensured by means of thrust−resil-ient elastomer bearings for motion absorption between bedplate “II“ (3.2) andbedplate “III“ (3.3). Bedplate “IV“ (3.4) is permanently connected with the rotary−kilnfoundation.

Bearing corrections (e.g. for compensating foundation settlements) are carried outby means of correcting plates between bedplate “III“ (3.3) and bedplate “IV“ (3.4).To avoid impermissibly high temperatures at the elastomer bearings for motionabsorption (3.10), bedplate “II“ (3.2) is cooled with cooling water from the supportingroller bearings.

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Supporting roller centering device

The rollers (1.0) of supporting roller station “I“ and the outward−running supportingroller of roller station “II“ are equipped with a position control system. The supportingrollers are therefore held in an approximately central position. The position sensingis performed via the distance sensors (3.13). The rollers are adjusted via the controlsystem by means of the adjusting spindles (3.11).

Central bed plate

The rotary kiln axial thrust system is bolted onto the central bed plate.

The tyre saddle (3.6) is bolted onto the central bed plate (3.5) and secures the rotarykiln if components of the self–aligning roller station fail.

To facilitate repair work (e.g. replacement of a supporting roller), you can set the kilntyre down on the tyre saddle. You can also fit hydraulic jacks into the tyre saddle inorder to lift the kiln tyre station independently of the supporting rollers afterunscrewing the fixing bolts.

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4 Transport and assembly

4.1 Transport and storage instructions

The supporting roller station is delivered in individual component parts. It must beensured that suitable lifting equipment is employed for lifting the parts from thetransport vehicles and transferring them to the storage area.

When they arrive at the site, all parts must be inspected for transport damage andplaced on wooden beams with the provision of suitable protection against moisture,soiling and damage. Never place the parts directly on the ground.

Check the corrosion proofing and renew it if necessary.

Measurement and control equipment must be stored in well−ventilated buildings andmust be protected against moisture.

4.2 Assembly

General notes

The following assembly instructions do not detail the individual steps for assemblingthe machine units but rather give an overview of the work to be performed.

Changes in the planning of the plant during the processing of the contract may leadto deviations from these assembly instructions.

NOTEIt is a prerequisite of our warranty that assembly and assembly inspection areundertaken by an assembly specialist from POLYSIUS AG

A careful selection of the tools and appliances as well as the assembly personnelto be employed is important for the correct performance of the work.

CAUTIONIf you carry out electrical welding on any part of the machine, never conductthe welding current through plain or antifriction bearings, other movingconnecting elements or measuring devices, in order to prevent damage tothese parts.Always directly connect the welding current return lead to the part beingwelded.

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Measuring work

Elevation reference point

The starting point of all measuring work is the elevation reference point which appliesto the entire plant and which has a fixed relationship to the zero datum line shownin the general arrangement drawing. The companies responsible for construction ofthe foundations and buildings determine the elevation reference point and inform ourerection superintendent accordingly.

To facilitate the measurements of axes and heights for the purpose of assemblingthe machine components, inscribe a benchmark of, for instance, 1000 mm abovezero datum line on every rotary−kiln foundation. For this purpose, the constructionfirm anchored steel plates sized 200 x 200 mm on 4 corners of each foundation.Determine the height by levelling instrument or rubber tube level and permanentlychisel it as benchmark into the steel plates.

Figure 12

A = datum mark B = steel plate

C = anchorage D = concrete

E = drilled hole for nailed connection to formwork

This ”1 metre mark” enables any foundation subsidences to be determined bymeans of subsequent check measurements. For this reason, the same benchmarksmust also be attached to the preheater and cooler buildings.

The bedplates of the supporting roller stations are provided with measuring marksby the manufacturer.

The check measurements must be written into a measurement record (with sketch)and their correctness must be confirmed by the customer.

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Sequence of assembly

Laying base girders

− After concluding the measuring work, first align bedplates ”IV” (3.4) and thengrout in with non–shrink grout.

Mounting and aligning the bedplates

− Place bedplates „I, II, III“ onto the bedplates “IV“ grouted in and align. Replacethe elastomer bearings for motion absorption during this work with steel auxiliarydevices of equal size, i.e. the roller station is not self−aligning in this condition.For the alignment, packing plates can be inserted between the bedplates “III“and “IV“.

− After concluding the aligning work, lock bedplate “III“ on bedplate “IV“ by meansof the lateral keys. Secure the keys by means of a weld seam.

− Then place the bearings onto the bedplates.

Mount the roller station with plain bearings (if not already mounted)

− Remove the corrosion proofing from the roller shaft ends.

− Clean the bearing housing, remove the bearing cover and check that the bearingbushes with thrust ring are correctly installed.

− Slip the bearing onto the roller shaft end, mount the thrust disks (2.31) andadapter (2.21) and tighten and secure the bolts and locking washers with thestipulated torque.

− Mount and secure the oil scoops. Seal and mount the bearing cover.

− Install the shaft seals.

− Clean the contact surfaces of the bearing and coat with graphite paste or similar.

− Insert the sliders and place the rollers and ready−mounted bearings onbedplates ”I”.

CAUTION To prevent damage to the top side of the axle journal while transporting thetrack roller with axle and bearing as a unit, insert a suitable wooden blockbetween the axle journal and the inner side of bearing. After setting the unit(roller, axle and bearing) down on bedplate ”I”, remove the wooden blockimmediately.

− Insert the bearing positioning units with thrust elements.

− Adjust the supporting roller axle to the dimensions stipulated in the generalarrangement drawing and the measurement record.

− Check the angles of inclination of foundations, bedplates and supporting rolleraxes relative to the kiln inlet housing and cooler using POLSCANr.

− Permanently mark the set dimensions on the seat of the bedplates and at thebearing base.

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− Protect the bearing positioning units against damage and dirtying of the threadedspindle by means of protective boxes.

− Mount and align the heat shields, guard plates and graphite lubrication deviceson the supporting–roller bearing.

− Fill with oil in accordance with the lubrication instructions (section Lubrication).

− Before commissioning the rotary kiln, remove the steel auxiliary devices andreplace the elastomer bearings for motion absorption.

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Lubrication

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5 Lubrication

NOTEThe POLYSIUS table of lubricants with the lubricant reference numbers iscontained in the supplement Important notes on the documentation. Thesupplement is contained in this folder or at the beginning of the overalldocumentation. Each lubricant has a clear reference number to which the lubricationinstructions in this section relate. The table gives a complete list of all suppliers andproducts approved by POLYSIUS AG.It is the responsibility of the lubricant supplier to select appropriate lubricantscorresponding to the lubricant reference numbers. POLYSIUS AG accepts noliability for the correctness of this data.If you wish to use a lubricant that is not included in the Table of lubricants, you haveto first obtain the express permission of POLYSIUS AG.The supplement Important notes on the documentation also contains the generallyvalid Notes on lubrication.

Ensure that the environment is not polluted when lubricants are stored, usedand disposed of and carefully observe the relevant national legislation for theprotection of the environment when handling lubricants..

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Lubrication

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Lubrication chart

A b

Figure 13

oil level mark at the oil sight glass.An excessive oil level in the supporting roller bearing causesleaks.

Figure 14

CAUTIONSynthetic oils on polyethylene glycol basis attack the material of the bearingbushes in the supporting roller bearings. (Lubrication points No. 11 and 12)Never use synthetic oils on a polyethylene glycol basis for lubricating thebearings of the roller stations.Be sure to regularly check the oil levels in the oil sight glasses of all thesup-porting–roller bearings.

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Lubrication

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Lubrication points Quantity (ltr, kg) per lubrication

point

Lubrication intervals (weeks)

No. Qty. Designation Lubricant ref.no.

Initial fill-ing

Topping up Toppingup

Firstchange

Furtherchanges

11 4 Supporting roller bearingstation ”I” �

26 4 24

12 4 Supporting roller bearingstation ”II” �

26 4 24

13a 1 Graphite lubrication devicestation ”I”

Check the graphite blocks daily for wear.Only the two outer fields may be filled with 100 mm wide graphite blocks.

13B 1 Graphite lubrication devicestation ”II”

Check the graphite blocks daily for wear.Apply graphite blocks over the entire supporting roller width.

14 Hydraulic direct drive Acc. to manufacturer’s instructions

The different makes of lubricant corresponding to the lubricant reference numbers are shown in the Table of lubricants in thesupplement Important notes on the documentation. The supplement is contained in this folder or at the beginning of the overalldocumentation.

Explanation of the numbers

� Check the oil level at the oil sight glass of the downhill and uphill supporting roller bearings every week,see Figure 14.

CAUTION at the supporting roller bearings.When the rotary kiln is starting up and when the kiln rotation speed is n < 1min−1 the oil pumps of the supporting–roller bearings have to be in operation.

When the rotary kiln is starting up the axles in the supporting–roller bearings (2) haveto be covered with a film of lubricating oil. The self−lubrication by means of the oilscoops does not begin until after about a half rotation of the rollers.

The supporting–roller bearings must therefore be prelubricated for 2 to 5 minutes bymeans of the oil pumps (2.15).

Lubricant supply to the supporting−roller bearings when the kiln rotation-speed is below one rotation per minute

During operation with kiln rotation speeds of n < 1 min−1 the axles inthesupporting–roller bearings (2) have to be supplied with sufficient lubricating oil.

This is done by means of the oil pumps (2.15).

NOTEIf one oil pump fails at operating speed, a warning is issued.

Machine manual


Lubrication

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At this speed of rotation the oil scoops assure that sufficient lubricant is supplied tothe supporting–roller bearing.

Machine manual


Preparation for test run

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6 Preparation for test run

NOTEIt is a prerequisite of our warranty that the first test run is carried out in the presenceof and according to the instructions of specialists from POLYSIUS AG.

6.1 Checks prior to the test run

After completing the assembly work and prior to the first test run, check all parts ofthe plant in accordance with the list below. Make absolutely sure that any materialremnants, tools and assembly implements have been carefully removed.

− Are all inspection ports in the bearings closed?

− Are all stations correctly aligned?

− Is the control system for supporting roller adjustment at stations “I“ and “II“ready for operation?

− Are the supporting roller centering devices with distance sensors (3.13) readyfor operation?

− Have all transportation aids and securing devices been removed?

− Are the rollers of station “I“ and “II“ in non−angled position?

− Is the bearing temperature monitoring system (option) ready for operation?

− Is the total clearance between the thrust disks and the half thrust rings inaccordance with the dimensions stipulated in the data sheet?

− Is the cooling device at the supporting–roller bearings and bedplate ”II” inoperation?

− Is the coolant pressure of the closed cooling circuit less than 2 bar?

− Is the feed flow coolant temperature below 30 °C?

− Are the graphite slabs for supporting–roller lubrication installed at stations “I“and “II“?

− Have the components been filled with the correct lubricant in accordance withthelubrication instructions?

− Does the lubricant level correspond to the stipulated height in the bearinginspection glass?

− Is the circulation lubrication system for the bearings in operation (prelubricationperiod 2 to 5 minutes)?

Machine manual


Preparation for test run

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6.2 Setting and adjustment

In the initial phase of commissioning you have to constantly check the setting andtemperature development of the supporting–roller bearings. If necessary, you willhave to carry out fine adjustments to the bearing alignment while the rotary kiln isrunning.

When carrying out fine alignment of the inward–turning supporting roller of station“II“, pay attention to the oil film on the shaft journal and check the temperaturedevelopment of the thrust disks.

This work demands considerable special knowledge and may only be carried outunder the direction of specialists from POLYSIUS AG.

At the driven roller station ”I“, a control system ensures the correct adjustment ofthe rollers.

Machine manual


Maintenance

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7 Maintenance

DANGERThe rotary kiln is hot.You may suffer very severe burns!Always use the required protective clothing.

No. Work to be performed Frequency Comments

1 Check the lubricant level in thesupporting–roller bearings.

Weekly You can see thelubricant filling level inthe oil sight glass onthe outer bearing face.

2 Check the bearing temperaturePermissible value:60 °C at the bearing bush(can only be determined with bearingtemperature measuring system [option]) and50 °C at the bearing housing.

Daily

3 Check the inlet temperature of the coolant. weekly Required value < 30 °C

4 Check the outlet temperature of the coolant. Weekly Required value < 45 °C

5 Check the coolant pressure(only in the case of closed systems)

Weekly Required value < 2 bar

6 Check the axial play between the thrustdisks and half thrust rings.

Every 6 months

7 Check the contact pattern of the rollers. Daily

8 Check the graphite lubrication device forwear at stations “I“ and “II“.

Daily

9 Check the supporting–roller bearings forleaks.

Weekly

10 Check the foundations for settlement ortilting.Measure the reference marks on thefoundations.

Every 3 months If only slight move-ments are measured-within one period, youcan increase theintervals to 1 x peryear.

Machine manual


Maintenance

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7.1 Servicing

DANGERThe rotary kiln is hot.You may suffer very severe burns!Always use the required protective clothing.

No. Work to be performed Frequency Comments

1 Change the bearing lubricant. See section Lubrica-tion

2 Replace the graphite slabs of thesupporting–roller lubrication system.

Depending on wear condition

7.2 Trouble shooting

Fault Cause Elimination

Foundation movements of� 5 mm since the lastcheck (adjustment).

Foundation subsidence POLSCANr personnel measureand, if necessary, readjust thesupporting rollers and the rotary kilnaxis with the POLYSIUS AGmeasuring system by order and foraccount of the customer.

Foundation tilting POLYSIUS AG personnel measureand, if necessary, readjust the sup-porting rollers and the rotary kilnaxis by underlaying bedplate ”III”with the aid of the POLSCANr measuring system by order and foraccount of the customer.

Leaks at the shaftpassa-ges.

Mismatch of centres dueto wear of the bearingbushes

Retension the stuffing box gland.

Loosen the tensioning bolts oftherespective centering ring.

This measure will recentre the seals.

Then retighten the tensioning bolts.

Worn seals Replace the seals and packings.

Machine manual


Maintenance

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EliminationCauseFault

Overheating of thesupporting roller bearing.

Lack of lubricant Open the upper bearing cover andfill in lubricant.

The lubricant does notcomply with the lubricantrecommendation

Change the lubricant.

Attention:When changing the lubricant ensurethat no foreign bodies get into thesupporting roller bearing.

Lack of coolant Ensure that the supply of coolant isadequate.

Angling of the supportingroller bearing (the contactpressure between thethrust ring and the thrustdisks is too high)(only station “II“)

Readjust the supporting rollerbearing until there is only slightcontact.

Attention:This work may only be performed byexperts.

Lack of lubricant due toexcessive axial clearancebetween the thrust disksand the half thrust rings

Check the clearance in accordancewith the dimensions stated in sectionTechnical data. Reduce theclearance by underlaying the sliders(5) with packing plates.

Lack of lubricant due toinsufficient delivery by theoil scoops

D Oil scoops are not fillingadequately

Check the lubricant level.

Check the oil scoops to see if thevent in the partition is clogged up.(the scoops are possibly not filledadequately because the air cushion-cannot escape.)

D Low kiln rotation speed(< 1 min−1) over alengthy period of time

Check the functioning of the oilpumps (2.15).

Failure of the positioncontrol system at station“I“ or “II“

Check and repair the control loopfrom the distance sensors to thead-justing spindles.

If any faults occur which are not described above, consult the additional informationabout faults, their causes and their elimination in the subsuppliers’ documentation.

Machine manual


Maintenance

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7.3 RepairBefore beginning any repair work, switch off the power supply to all electricalcomponents.Ensure absolute cleanliness at all times during repair work in order to prevent dirtfrom entering the bearings, the drive units or other sensitive parts of the machine orplant.Do not remove or open any covers or protection devices before all rotating parts havestopped.

DANGERYou may burn yourself!It is forbidden to carry out work at the rotating kiln.Before beginning any repair work, make absolutely sure that the rotary kilnhas swung to a complete stop in its centre of gravity position and has beensecured by means of the holding brake!Always use the required protective clothing.

As a rule, it is only possible to carry out repair work on the supporting rollerstationsafter dismounting the supporting–roller bearing or the rollers.

− Mark the position of the supporting–roller bearings relative to the bedplate by,forexample, chisel or punch marks.

− Unscrew the front–side bearing cover.

− Detach the bolted connections at the thrust disk.

− Remove the thrust disk.

− Withdraw the supporting–roller bearing in axial direction of kiln.

Assemble in reverse orderBe sure to observe the tightening torque of the bolts at the thrust disks.

Bolt diameter (mm) Tightening torque (Nm)

M 30 1200

M 33 1700

M 36 2150

M 39 2850

M 42 3500

M 48 5300

M 52 6950

M 56 8600

M 60 10900

M 64 13100

After tightening these bolts, secure them against loosening by means of suitablelocking wire.

Machine manual


Maintenance

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Check the condition of the bearing bushes and the shaft ends every time.

If you find scoring on the shaft ends, replace the bearing bushes in pairs and thensmooth out the grooves.

Subsequently, clean the supporting–roller bearings and fill with new lubricant.

In order to improve the contact pattern, it is possible to grind the surfaces of therollers and tyres with a special roller / tyre grinder during normal kiln operation.

CAUTIONAfter you have completed the repair work, you must check the machine/plantagain according to section Preparation for test run.

Tools and implements

No special tools are required for repair work on the machine. However, you may needtorque wrenches of a bigger size than normal.

Whether or not you need auxiliary equipment, such as scaffolds or hoists, dependson the conditions in your plant.

Machine manual


Spare parts

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8 Spare parts

Notes for enquiring about and ordering spare parts

Dear Customer,

POLYSIUS AG strive to render your enquiring about and ordering of spare parts aseasy, and as a consequence, as efficient as possible. For this purpose we haveprepared a table containing all data required by our spare parts department to ensureoptimum processing in the most speedy and troublefree manner.

Please copy the page with the respective table and mark those parts which yourequire with a cross in the column Order or Enquiry.

If the table relates to more than one machine, please also inform us of the AAT itemof the machine for which you require the spare parts.

Machine manual


Spare parts

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Spare parts for supporting roller station “I“

Figure 15

Machine manual


Spare parts

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Code word: Order No.: AAT-item:

Item Designation Qty. Unit Order Enquiry

1.0 Supporting roller with axle 1 Piece

1.1 Graphite block lubrication 1 Set

3.1.1 Bedplate ”I” 1 Piece

3.2 Bedplate ”II” 1 Piece

3.3 Bedplate “III“ 1 Piece

3.4 Bedplate “IV“ 1 Piece

3.9 Elastomer bearing for motionabsorption 1 Set


3.11 Adjusting spindle 2 Piece

3.13 Distance sensor 2 Piece

Machine manual


Spare parts

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Spare parts for the supporting–roller bearing (2.1) in roller station “I“

Figure 16

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Spare parts

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2.1 Supporting roller bearing, com-plete 1 Piece

2.3 Bearing housing 1 Piece

2.4 Bearing bush 1 Piece

2.5 Half thrust ring 1 Piece

2.6 Oil scoop 1 Piece

2.7 Inspection cover 1 Piece

2.7.1 Seal 1 Piece


2.8.1 Seal 1 Piece

2.9 Venting connection 1 Piece

2.10 Splash ring 1 Piece

2.11 Centering ring 1 Piece

2.11.1 Tensioning screw 1 Piece

2.11.2 Guide strip 1 Piece

2.12 O ring 1 Piece

2.13 Stuffing box gland 1 Piece


2.13.2 Packing 1 Set

2.13.3 Scraper ring 1 Piece

2.14 Lubricant inspection glass 1 Piece

2.15 Oil pump 1 Piece

2.16 Bearing cover 1 Piece




2.18 O ring 1 Piece





2.20 Transverse key 1 Piece

2.21 Adapter 1 Piece

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Spare parts

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Spare parts for supporting roller station “II“

Figure 17

Machine manual


Spare parts

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1.0 Supporting roller with axle 1 Piece

1.2 Graphite block lubrication 1 Set

3.1.2 Bedplate ”I” 1 Piece

3.2 Bedplate ”II” 1 Piece

3.3 Bedplate “III“ 1 Piece

3.4 Bedplate “IV“ 1 Piece



3.11 Adjusting spindle 1 Piece

3.12 Distance sensor, tyre 1 Piece

3.13 Distance sensor, roller 1 Piece

Machine manual


Spare parts

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Spare parts for the supporting–roller bearing (2.2) in roller station “II“

Figure 18

Machine manual


Spare parts

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2.2 Supporting roller bearing, com-plete 1 Piece

2.3 Bearing housing 1 Piece

2.4 Bearing bush 1 Piece

2.5 Half thrust ring 1 Piece

2.6 Oil scoop 1 Piece


2.7.1 Seal 1 Piece


2.8.1 Seal 1 Piece

2.9 Venting connection 1 Piece

2.10 Splash ring 1 Piece




2.12 O ring 1 Piece





2.14 Lubricant inspection glass 1 Piece

2.15 Oil pump 1 Piece

2.30 Bearing cover 1 Piece

2.31 Thrust disc 1 Piece

Machine manual


Appendix

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9 Appendix

9.1 Technical drawings

Designation Drawing no.

Assembly drawing

Oil circulation lubricating system

9.2 Subsuppliers’ documentation

Oil pump

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EN21004243A Roller Stations

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