EN21004243A Roller Stations

Machine manual
en-21004.243-A
POLRO
r
selfaligning roller station
for mechanical direct drive
(2 roller drive)
Code word
Order No.
AAT items
Machine manual
POLRO
r
selfaligning roller station for mechanical direct drive (2 roller drive)
Contents
en-21004.243-A
Contents
1 Technical data 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 Safety 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Components and mode of functioning 31 . . . . . . . . . . . . . . . . . . . . .
3.1 Components 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Mode of functioning 318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 Transport and assembly 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 Transport and storage instructions 41 . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Assembly 41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Lubrication 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Preparation for test run 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Checks prior to the test run 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Setting and adjustment 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 Maintenance 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 Servicing 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Trouble shooting 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Repair 74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 Spare parts 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Appendix 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 Technical drawings 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Subsuppliers documentation 91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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selfaligning roller station for mechanical direct drive (2 roller drive) 11
Technical data
en-21004.243-A
1 Technical data
NOTE
Information concerning the electrical equipment is contained in the separate
electrical 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety
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2 Safety
NOTE
Be sure to comply with the general safety instructions in the supplement Important
notes 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 Technical
data.
D Any use other than the intended use is forbidden. POLYSIUS AG is not
responsible for damage resulting from any use other than the intended use. All
other use is at the owners own risk.
D The intended use also includes the observance of the instructions in the machine
manual and the compliance with the maintenance instructions.
Transport and assembly
D All transportation instructions in this machine manual refer exclusively to
transportation of the machine at the plant site.
D Only use suitable hoisting and lifting equipment which is in serviceable order and
has 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 national
regulations. The plant management is responsible for the performance and
recording of such checks.
D If changes in the machine or its operating behaviour relevant to safety occur, shut
it down immediately.
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Safety
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Maintenance
D Ensure that all machines and motors whose operation might endanger persons
or equipment are switched off and safeguarded against restarting for the entire
duration of the maintenance work.
D Ensure that all rotating parts of the machine have come to a complete standstill
before you remove any protection devices or open any flaps.
D Before performing any work on the machine, make sure there is no risk of burns
when touching the machine.
D After opening the top cover of the bearing, do not insert fingers or hands into the
bearing: danger of crushing or tearing off due to rotating oil scoops.
D Keep the machine free of oily and combustible substances and materials. Never
use gasoline or other easily inflammable substances for cleaning the machine.
D Switch off the power supply to the electrical components before commencing any
maintenance work.
D The plant management has to ensure that the whole area of the rotary kiln is
cordoned off, so that it is impossible for persons to come into contact with rotating
parts.
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 has
swung to a complete stop in its centre of gravity position and has been secured
by 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 the
welding current through plain or antifriction bearings, other movable connections
or measuring devices. Always directly connect the welding current return lead to
the part being welded.
D Remount all protection devices when maintenance work has been finished. Make
absolutely sure that no persons are inside the plant component before you
properly close the inspection and service covers.
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Components and mode of functioning
en-21004.243-A
3 Components and mode of functioning
The rotary kiln is supported on the supporting roller stations I and II of the two
tyres; the occurring forces are transmitted into the foundations.
The roller stations are mounted on selfaligning bedplates that are fixed onto the
foundations.
The rollers of supporting roller station I are directly driven via the adapters.
3.1 Components
NOTE
Some details of the drawings in this manual may not be identical with the drawings
supplied under the contract as listed in section 9.1 Technical drawings.
Each supporting roller station essentially consists of the following components:
D the selfaligning 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 selfaligning 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 Selfaligning bed plate unit for roller station I
3.0.2 Selfaligning 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 selfaligning 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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Roller station I
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
NOTE
The 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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Roller station I
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 Oring
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 Oring
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 selfaligning 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 selfaligning bed plate unit (3.0.2)
3.6 Tyre saddle
3.11 Adjusting spindle with position sensor
3.13 Distance sensor, roller
NOTE
The 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 Oring
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 functioning
For supporting the rotary kiln, each roller station requires two rollers with one pair
of bearings each, plus the associated bed plate units.
As a rule, the rollers are so arranged that the connecting lines from the centre of the
roller 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 and
transferred into the foundation.
The dimensions of the kiln tyre and the supporting rollers, as well as those of all roller
station components are selected to suit the expected operating conditions of the
respective rotary kiln.
To ensure a good contact pattern and avoid impermissibly high local Hertzian
pressures between a wobbling tyre and the supporting rollers, the rollers have a
selfaligning supporting system.
In combination with a direct drive system, the rollers also transmit the driving torque
to the kiln tyre. The drive acts on one or two rollers of one station.
Supporting rollers and axles
The cast or forged solid section rollers are nondetachably connected to the forged
supporting roller axles and have drill holes for transportation purposes.
The axle ends have been prepared for receiving the adapter of the direct drive
system.
Supportingroller bearings
The bearings consist of a cast housing with integrated coolant compartments and
of the bearing bush halves and the collar ring halves made of a special bearing metal
with very good emergency running characteristics.
The supportingroller bearings are so designed that PT 100 temperature sensors
can be installed.
The axle ends are mounted in the bearing bushes. Axial forces are transmitted via
the thrust rings bolted onto the axle to the collar of the bearing bushes and the half
thrust rings.
The plain bearings are lubricated with mineral oil (see section Lubrication). Oil
scoops 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 wedgeshaped inlet gap on the inwardturning side
of the bearing bush, is distributed over the entire length of the bearing bush and
passes 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 rotation
speeds, the supportingroller bearings are equipped with oil pumps. It is wise to
observe a prelubrication period of approx. 25 minutes before starting to turn the kiln.
However, for safety reasons the lubrication during operation is performed by the oil
scoops.
The coolant for the supportingroller bearings (generally cooling water) flows
through cooling compartments in the bearing base.
In order to correct the position of the rotary kiln, you can shift the supportingroller
bearings (and thus the rollers) transverse to the rotary kiln axis by using the bearing
positioning units.
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You can perform this adjustment under operating load, as the bearing positioning
units are designed to accept a hydraulic bearing adjustment device. You have to
adjust both bearings of one supportingroller 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 adjustment
as described above. Then remove the hydraulic press.
When readjusting the supportingroller bearings pay attention that no impermissible
heating up of the thrust disks and collar rings occurs, as this is a sign of skewing of
the supporting roller axis relative to the rotary kiln axis, which can cause
impermissibly high axial forces.
The supportingroller 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 suited
to the rotary kiln operation and are pressureresistant and thrustresilient. These
bearings permit deflection in the case of a wobbling kiln tyre in spite of great
operating loads.
The elastomer bearings for motion absorption must be protected against oils,
greases, chemicals etc. as this considerably reduces serviceability.
Selfaligning bed plate unit
The pair of bearings belonging to each supporting roller is movably mounted on the
bedplates I (3.1.1 and 3.1.2) and is only secured by the bearing positioning units.
This provides the possibility to preset the supportingroller bearing relative to the
rotary kiln axis.
The spreading forces are transmitted via the tension rods (3.7) and the central bed
plate (3.5).
At supporting roller stations I and II, the bedplates I (3.1.1 and 3.1.2) are
movable 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 of
the supporting roller relative to the rotary kiln axis during normal kiln operation.
Selfalignment of the supporting roller station is ensured by means of thrustresil-
ient elastomer bearings for motion absorption between bedplate II (3.2) and
bedplate III (3.3). Bedplate IV (3.4) is permanently connected with the rotarykiln
foundation.
Bearing corrections (e.g. for compensating foundation settlements) are carried out
by means of correcting plates between bedplate III (3.3) and bedplate IV (3.4).
To avoid impermissibly high temperatures at the elastomer bearings for motion
absorption (3.10), bedplate II (3.2) is cooled with cooling water from the supporting
roller bearings.
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Supporting roller centering device
The rollers (1.0) of supporting roller station I and the outwardrunning supporting
roller of roller station II are equipped with a position control system. The supporting
rollers are therefore held in an approximately central position. The position sensing
is performed via the distance sensors (3.13). The rollers are adjusted via the control
system 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 rotary
kiln if components of the selfaligning roller station fail.
To facilitate repair work (e.g. replacement of a supporting roller), you can set the kiln
tyre down on the tyre saddle. You can also fit hydraulic jacks into the tyre saddle in
order to lift the kiln tyre station independently of the supporting rollers after
unscrewing 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 be
ensured that suitable lifting equipment is employed for lifting the parts from the
transport vehicles and transferring them to the storage area.
When they arrive at the site, all parts must be inspected for transport damage and
placed 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 wellventilated buildings and
must be protected against moisture.
4.2 Assembly
General notes
The following assembly instructions do not detail the individual steps for assembling
the 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 lead
to deviations from these assembly instructions.
NOTE
It is a prerequisite of our warranty that assembly and assembly inspection are
undertaken by an assembly specialist from POLYSIUS AG
A careful selection of the tools and appliances as well as the assembly personnel
to be employed is important for the correct performance of the work.
CAUTION
If you carry out electrical welding on any part of the machine, never conduct
the welding current through plain or antifriction bearings, other moving
connecting elements or measuring devices, in order to prevent damage to
these parts.
Always directly connect the welding current return lead to the part being
welded.
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Measuring work
Elevation reference point
The starting point of all measuring work is the elevation reference point which applies
to the entire plant and which has a fixed relationship to the zero datum line shown
in the general arrangement drawing. The companies responsible for construction of
the foundations and buildings determine the elevation reference point and inform our
erection superintendent accordingly.
To facilitate the measurements of axes and heights for the purpose of assembling
the machine components, inscribe a benchmark of, for instance, 1000 mm above
zero datum line on every rotarykiln foundation. For this purpose, the construction
firm 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 permanently
chisel 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 by
means of subsequent check measurements. For this reason, the same benchmarks
must also be attached to the preheater and cooler buildings.
The bedplates of the supporting roller stations are provided with measuring marks
by 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 then
grout in with nonshrink grout.
Mounting and aligning the bedplates
Place bedplates I, II, III onto the bedplates IV grouted in and align. Replace
the elastomer bearings for motion absorption during this work with steel auxiliary
devices of equal size, i.e. the roller station is not selfaligning 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 means
of 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 bearing
bushes with thrust ring are correctly installed.
Slip the bearing onto the roller shaft end, mount the thrust disks (2.31) and
adapter (2.21) and tighten and secure the bolts and locking washers with the
stipulated 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 readymounted bearings on
bedplates I.
CAUTION
To prevent damage to the top side of the axle journal while transporting the
track roller with axle and bearing as a unit, insert a suitable wooden block
between the axle journal and the inner side of bearing. After setting the unit
(roller, axle and bearing) down on bedplate I, remove the wooden block
immediately.
Insert the bearing positioning units with thrust elements.
Adjust the supporting roller axle to the dimensions stipulated in the general
arrangement drawing and the measurement record.
Check the angles of inclination of foundations, bedplates and supporting roller
axes relative to the kiln inlet housing and cooler using POLSCAN
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.
Permanently mark the set dimensions on the seat of the bedplates and at the
bearing base.
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Protect the bearing positioning units against damage and dirtying of the threaded
spindle by means of protective boxes.
Mount and align the heat shields, guard plates and graphite lubrication devices
on the supportingroller bearing.
Fill with oil in accordance with the lubrication instructions (section Lubrication).
Before commissioning the rotary kiln, remove the steel auxiliary devices and
replace the elastomer bearings for motion absorption.
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Lubrication
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5 Lubrication
NOTE
The POLYSIUS table of lubricants with the lubricant reference numbers is
contained in the supplement Important notes on the documentation. The
supplement is contained in this folder or at the beginning of the overall
documentation. Each lubricant has a clear reference number to which the lubrication
instructions in this section relate. The table gives a complete list of all suppliers and
products approved by POLYSIUS AG.
It is the responsibility of the lubricant supplier to select appropriate lubricants
corresponding to the lubricant reference numbers. POLYSIUS AG accepts no
liability for the correctness of this data.
If you wish to use a lubricant that is not included in the Table of lubricants, you have
to first obtain the express permission of POLYSIUS AG.
The supplement Important notes on the documentation also contains the generally
valid Notes on lubrication.
Ensure that the environment is not polluted when lubricants are stored, used
and disposed of and carefully observe the relevant national legislation for the
protection of the environment when handling lubricants..
Machine manual
POLRO
r
Lubrication
en-21004.243-A
Lubrication chart
A
b
Figure 13
oil level mark at the oil sight glass.
An excessive oil level in the supporting roller bearing causes
leaks.
Figure 14
CAUTION
Synthetic oils on polyethylene glycol basis attack the material of the bearing
bushes in the supporting roller bearings. (Lubrication points No. 11 and 12)
Never use synthetic oils on a polyethylene glycol basis for lubricating the
bearings of the roller stations.
Be sure to regularly check the oil levels in the oil sight glasses of all thesup-
portingroller bearings.
Machine manual
POLRO
r
Lubrication
en-21004.243-A
Lubrication points Quantity (ltr, kg)
per lubrication
point
Lubrication intervals
(weeks)
No. Qty. Designation Lubricant ref.
no.
Initial fill-
ing
Topping up Topping
up
First
change
Further
changes
11 4 Supporting roller bearing
station I
26 4 24
12 4 Supporting roller bearing
station II
26 4 24
13a 1 Graphite lubrication device
station 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 device
station II
Check the graphite blocks daily for wear.
Apply graphite blocks over the entire supporting roller width.
14 Hydraulic direct drive Acc. to manufacturers instructions
The different makes of lubricant corresponding to the lubricant reference numbers are shown in the Table of lubricants in the
supplement Important notes on the documentation. The supplement is contained in this folder or at the beginning of the overall
documentation.
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 < 1
min
1
the oil pumps of the supportingroller bearings have to be in operation.
When the rotary kiln is starting up the axles in the supportingroller bearings (2) have
to be covered with a film of lubricating oil. The selflubrication by means of the oil
scoops does not begin until after about a half rotation of the rollers.
The supportingroller bearings must therefore be prelubricated for 2 to 5 minutes by
means of the oil pumps (2.15).
Lubricant supply to the supportingroller 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 in
thesupportingroller bearings (2) have to be supplied with sufficient lubricating oil.
This is done by means of the oil pumps (2.15).
NOTE
If one oil pump fails at operating speed, a warning is issued.
Machine manual
POLRO
r
Lubrication
en-21004.243-A
At this speed of rotation the oil scoops assure that sufficient lubricant is supplied to
the supportingroller bearing.
Machine manual
POLRO
r
Preparation for test run
en-21004.243-A
6 Preparation for test run
NOTE
It is a prerequisite of our warranty that the first test run is carried out in the presence
of 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 of
the plant in accordance with the list below. Make absolutely sure that any material
remnants, 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) ready
for operation?
Have all transportation aids and securing devices been removed?
Are the rollers of station I and II in nonangled position?
Is the bearing temperature monitoring system (option) ready for operation?
Is the total clearance between the thrust disks and the half thrust rings in
accordance with the dimensions stipulated in the data sheet?
Is the cooling device at the supportingroller bearings and bedplate II in
operation?
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 supportingroller lubrication installed at stations I
and II?
Have the components been filled with the correct lubricant in accordance with
thelubrication instructions?
Does the lubricant level correspond to the stipulated height in the bearing
inspection glass?
Is the circulation lubrication system for the bearings in operation (prelubrication
period 2 to 5 minutes)?
Machine manual
POLRO
r
Preparation for test run
en-21004.243-A
6.2 Setting and adjustment
In the initial phase of commissioning you have to constantly check the setting and
temperature development of the supportingroller bearings. If necessary, you will
have to carry out fine adjustments to the bearing alignment while the rotary kiln is
running.
When carrying out fine alignment of the inwardturning supporting roller of station
II, pay attention to the oil film on the shaft journal and check the temperature
development of the thrust disks.
This work demands considerable special knowledge and may only be carried out
under the direction of specialists from POLYSIUS AG.
At the driven roller station I, a control system ensures the correct adjustment of
the rollers.
Machine manual
POLRO
r
Maintenance
en-21004.243-A
7 Maintenance
DANGER
The 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 the
supportingroller bearings.
Weekly You can see the
lubricant filling level in
the oil sight glass on
the outer bearing face.
2 Check the bearing temperature
Permissible value:
60 C at the bearing bush
(can only be determined with bearing
temperature measuring system [option]) and
50 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 thrust
disks and half thrust rings.
Every 6 months
7 Check the contact pattern of the rollers. Daily
8 Check the graphite lubrication device for
wear at stations I and II.
Daily
9 Check the supportingroller bearings for
leaks.
Weekly
10 Check the foundations for settlement or
tilting.
Measure the reference marks on the
foundations.
Every 3 months If only slight move-
ments are measured-
within one period, you
can increase the
intervals to 1 x per
year.
Machine manual
POLRO
r
Maintenance
en-21004.243-A
7.1 Servicing
DANGER
The rotary kiln is hot.
You may suffer very severe burns!
No. Work to be performed Frequency Comments
1 Change the bearing lubricant. See section Lubrica-
tion
2 Replace the graphite slabs of the
supportingroller lubrication system.
Depending on
wear condition
7.2 Trouble shooting
Fault Cause Elimination
Foundation movements of
w 5 mm since the last
check (adjustment).
Foundation subsidence POLSCAN
r
personnel measure
and, if necessary, readjust the
supporting rollers and the rotary kiln
axis with the POLYSIUS AG
measuring system by order and for
account of the customer.
Foundation tilting POLYSIUS AG personnel measure
and, if necessary, readjust the sup-
porting rollers and the rotary kiln
axis by underlaying bedplate III
with the aid of the POLSCAN
r

measuring system by order and for
account of the customer.
Leaks at the shaftpassa-
ges.
Mismatch of centres due
to wear of the bearing
bushes
Retension the stuffing box gland.
Loosen the tensioning bolts of
therespective centering ring.
This measure will recentre the seals.
Then retighten the tensioning bolts.
Worn seals Replace the seals and packings.
Machine manual
POLRO
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Maintenance
en-21004.243-A
Elimination Cause Fault
Overheating of the
supporting roller bearing.
Lack of lubricant Open the upper bearing cover and
fill in lubricant.
The lubricant does not
comply with the lubricant
recommendation
Change the lubricant.
Attention:
When changing the lubricant ensure
that no foreign bodies get into the
supporting roller bearing.
Lack of coolant Ensure that the supply of coolant is
adequate.
Angling of the supporting
roller bearing (the contact
pressure between the
thrust ring and the thrust
disks is too high)
(only station II)
Readjust the supporting roller
bearing until there is only slight
contact.
Attention:
This work may only be performed by
experts.
Lack of lubricant due to
excessive axial clearance
between the thrust disks
and the half thrust rings
Check the clearance in accordance
with the dimensions stated in section
Technical data. Reduce the
clearance by underlaying the sliders
(5) with packing plates.
Lack of lubricant due to
insufficient delivery by the
oil scoops
D Oil scoops are not filling
adequately
Check the lubricant level.
Check the oil scoops to see if the
vent in the partition is clogged up.
(the scoops are possibly not filled
adequately because the air cushion-
cannot escape.)
D Low kiln rotation speed
(< 1 min
1
) over a
lengthy period of time
Check the functioning of the oil
pumps (2.15).
Failure of the position
control system at station
I or II
Check and repair the control loop
from the distance sensors to thead-
justing spindles.
If any faults occur which are not described above, consult the additional information
about faults, their causes and their elimination in the subsuppliers documentation.
Machine manual
POLRO
r
Maintenance
en-21004.243-A
7.3 Repair
Before beginning any repair work, switch off the power supply to all electrical
components.
Ensure absolute cleanliness at all times during repair work in order to prevent dirt
from entering the bearings, the drive units or other sensitive parts of the machine or
plant.
Do not remove or open any covers or protection devices before all rotating parts have
stopped.
DANGER
You 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 kiln
has swung to a complete stop in its centre of gravity position and has been
secured by means of the holding brake!
As a rule, it is only possible to carry out repair work on the supporting roller
stationsafter dismounting the supportingroller bearing or the rollers.
Mark the position of the supportingroller bearings relative to the bedplate by,for
example, chisel or punch marks.
Unscrew the frontside bearing cover.
Detach the bolted connections at the thrust disk.
Remove the thrust disk.
Withdraw the supportingroller bearing in axial direction of kiln.
Assemble in reverse order
Be 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 suitable
locking wire.
Machine manual
POLRO
r
Maintenance
en-21004.243-A
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 then
smooth out the grooves.
Subsequently, clean the supportingroller bearings and fill with new lubricant.
In order to improve the contact pattern, it is possible to grind the surfaces of the
rollers and tyres with a special roller / tyre grinder during normal kiln operation.
CAUTION
After you have completed the repair work, you must check the machine/plant
again according to section Preparation for test run.
Tools and implements
No special tools are required for repair work on the machine. However, you may need
torque wrenches of a bigger size than normal.
Whether or not you need auxiliary equipment, such as scaffolds or hoists, depends
on the conditions in your plant.
Machine manual
POLRO
r
Spare parts
en-21004.243-A
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 as
easy, and as a consequence, as efficient as possible. For this purpose we have
prepared a table containing all data required by our spare parts department to ensure
optimum processing in the most speedy and troublefree manner.
Please copy the page with the respective table and mark those parts which you
require 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 item
of the machine for which you require the spare parts.
Machine manual
POLRO
r
Spare parts
en-21004.243-A
Spare parts for supporting roller station I
Figure 15
Machine manual
POLRO
r
Spare parts
en-21004.243-A
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 motion
absorption
1 Set
3.10
absorption
1 Set
3.11 Adjusting spindle 2 Piece
3.13 Distance sensor 2 Piece
Machine manual
POLRO
r
Spare parts
en-21004.243-A
Spare parts for the supportingroller bearing (2.1) in roller station I
Figure 16
Machine manual
POLRO
r
Spare parts
en-21004.243-A
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
Machine manual
POLRO
r
Spare parts
en-21004.243-A
Spare parts for supporting roller station II
Figure 17
Machine manual
POLRO
r
Spare parts
en-21004.243-A
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
3.9
absorption
1 Set
3.10
absorption
1 Set
3.11 Adjusting spindle 1 Piece
3.12 Distance sensor, tyre 1 Piece
3.13 Distance sensor, roller 1 Piece
Machine manual
POLRO
r
Spare parts
en-21004.243-A
Spare parts for the supportingroller bearing (2.2) in roller station II
Figure 18
Machine manual
POLRO
r
Spare parts
en-21004.243-A
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
POLRO
r
Appendix
en-21004.243-A
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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