INSTRUCTION MANUAL

BURNER SUSPENSION , BS

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Installation, operation and maintenance

VIGERSLEV ALL 77 - 2500 VALBY - DENMARK 2040 AVENUE C - PA 18017-2188 BETHLEHEM USA CAPITAL TOWERS 180. KODAMBAKKAM HIGH ROAD, NUNGAMBAKKAM,- CHENNAI 600 034 - INDIA

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Contents:

Page:

1.

GENERAL NOTES

2.

CONSTRUCTION AND OPERATING PRINCIPLE

3.

INSTALLATION

4.

OPERATION (see section 2)

5.

MAINTENANCE

10

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APPENDICES:

Burner suspension
Carriage
Carriage, sectional view

I
II
III

Editor:

JS

Translator:

JRo

Approved by:

CLKJ

MGN code:

3K01

Pages:

17

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NOTE!
The present instruction manual is concerned with the situations which, according to
our experience, are the most likely to occur. An exhaustive enumeration of all conceivable situations which may occur during mounting, operation and maintenance
of the burner suspension cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in
the instruction manual, and which the client is/feels unable to handle, we would recommend that FLS be contacted without undue delay for advice on appropriate action.

1.

GENERAL NOTES
Burner suspension type BS is used for the retention and positioning of the kiln
burner on kilns featuring a separate cooler. The burner suspension can be used for
all standard burner types and all normal types of fuel.

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2.

CONSTRUCTION AND OPERATING PRINCIPLE

For arrangement, see Appendices I, II and III.
The main components of the burner suspension are:
Travel rails (09)
Burner carriage (05)
The burner carriage (05) which runs on travel rails (09) is driven by geared motor
(22) via the gearbox (21) and the drive wheels (23).
The gearbox is provided with a hexagonal shaft end (20) for manual operation of
the carriage in the event of power failure. The carriage can be operated by means
of a 36 mm ratchet spanner or similar tools. At the rear end, the carriage also features a hook (36) which can be used to pull back the burner carriage.
At the front, the burner carriage is provided with a single wheel pair (23) at the end
facing the kiln. There are two wheel pairs at the rear end, one on top of the rails
and one on the lower side. Normally only the lower wheel pair will be loaded. The
upper wheel pair will only be loaded when the kiln burner (10) has been removed
from the burner carriage.
The kiln burner (10) is suspended from burner carriage (05) via the supporting
beam (06) in manner allowing it to be turned 2 - 3 degrees in either direction, i.e.
horizontally as well as vertically. Horizontal adjustment is done by means of
ratchet drive (12), vertical adjustment by means of a hydraulic cylinder (16). After
the burner has been vertically adjusted, the hydraulic cylinder can be relieved by
means of lock nut (17).
If the kiln burner is provided with a burner set for gas and/or oil of the type G, OG
or TFSM, the supply will also include 2 lightweight carriages (08) for burner lance.
These carriages are intended for retention of the gas or oil burner lance when it is
retracted from the kiln.

3.

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INSTALLATION
See Appendices I, II and III.

3.1

Travel rails
ERECTION CHECK
Check the holes in the portals for the installation of cross beams (04)
Mount portals, cross beams for rail suspension (04) and travel rails (09) in accordance with directions given on assembly drawing.
Align the cross beams so that the rails are straight, if necessary by inserting intermediates between the portals and the cross beams.
The portals may be made of concrete or steel. If concrete is used, the bolt holes
must be grouted following the alignment and trial-run of the burner carriage (see
sub-section 3.2.).
Mount cross girders (07) and cross beam (03). (Should not be welded).
Mount cable carriage - including rails for same - in accordance with the directions
on assembly drawing.

3.2

Burner carriage
Dismantle the lower wheels on the carriage (05) and lift it onto the rails (09).
Remount the lower wheels.
The rear wheel set must grip the rail section with one wheel over and one wheel
under the rail.
ERECTION CHECK
Move the carriage forward and backward on the rails by means of the hexagonal
shaft end of the gearbox, and check that the movement of the carriage is not impeded in any way.
Mount the axial bearing (25) with locking ring in the movable cross frame (26) in
accordance with directions given on assembly drawing.
Mount guide pin (24) in the suspension frame (19) exactly as indicated on the
assembly drawing.
Mount the movable cross frame (26) in the front suspension frame so that the
guide pin (24) extends through the axial bearing and the hole in the suspension
frame. Then mount the suspension frame on the carriage.
Mount the handle (29) in accordance with directions on assembly drawing.

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7
Lift the rear suspension frame (13) into the carriage so that rollers (32) bear against
the lower side of rail (31). Secure the suspension frame using the appertaining
locking plates (30).
Mount the hydraulic pump (14). Install the hydraulic pipework (18) and connect pump and hydraulic cylinder (16) as indicated on the assembly drawing.
Assemble the cross member (15) and link bearing (33).
Remove stop blocks (35). Lift the cross member onto the suspension frame. Remount the stop blocks (35) and let the cross frame rest on the blocks.
Mount ratchet drive (12) between suspension frame and carriage.
Mount start/stop switches, limit switches as well as power connections to geared
motor (22) in accordance with the wiring diagrams.
Mount light-weight carriages (08) for burner lance (if included in supply).
ERECTION CHECK
Check that motor, limit switches and start/stop switches perform as intended
3.3

Suspension of burner
To prepare the kiln burner for operation, see separate instruction manual for this
unit.
Place the burner on the burners platform under the travels rails with the supporting
beam facing upwards,
Move the burner carriage across the burner so that the front suspension is situated
immediately over the cross pin (27) of the supporting beam. If necessary, the
movable cross frame (26) can be lifted by means of the handles (29).
Remove the locking blocks (28) and safety pin (34) from front and rear suspensions, respectively.
Lift the burner pipe so that the cross pin (27) moves into the slits in the movable
cross frame (26), while, at the same time, the rear fork on supporting beam (06)
engages the shaft in the link bearing (33).
Refit the locking blocks and the safety pin and lock the safety pin. Ease off the
burner pipe so that comes to rest in the carriage. Check also that the hydraulic
piston fits into the recess on the cross member.
Adjust the position of the burner on a provisional basis as indicated in section 2 so
that the burner pipe is flush with the kiln centre line. Final adjustment is carried
out when the burner is positioned in the kiln. See instruction manual for burner.

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ERECTION CHECK
Check that locking blocks (28) and safety pin (34) including split pin are correctly
positioned.

4.

OPERATION
After the burner has been positioned in the kiln, and the final adjustment of its position has been carried out, the hydraulic cylinder (14) must be relieved. This is
done by clamping the lock nut (16) fully against the cylinder, with subsequent depressurization of the hydraulic pump (14).
Prior to any downward adjustment of the burner pipe, the hydraulic system
must be pressurized. Afterwards, the lock nut is screwed downward to extent required - towards the cross member, with subsequent de-pressurization
of the hydraulic system.
If a vertical adjustment of the burner pipe is required, the hydraulic system
must be pressurized and the piston must be retracted until the desired position of the burner pipe has been achieved. Afterwards, the lock nut is firmly
tightened against the hydraulic cylinder and the hydraulic system is relieved.
Attention is drawn to the fact that the lock nut must not be adjusted unless
the hydraulic system is pressurized.

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In event of power failure which makes it necessary to move the burner carriage out of the kiln to avoid damage to the burner pipe, this must be done
manually, as follows:
Initially, the burner pipe must be adjusted to the horizontal position by pressurizing the hydraulic system, subsequently clamping the lock nut down
against the cross member. Finally, the hydraulic system must be relieved
again.
Now, the burner carriage can be moved out according to any of the two
methods described below::
1. By using a 36 mm ratchet spanner on the hexagonal shaft end of the
gearbox.
2. By pulling out the burner carriage using a suitable rope or similar
means attached to the tow hook at the rear end of the burner carriage.

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5.

MAINTENANCE

5.1

Preventive maintenance, summary

.1 Lubrication
.2 Cleaning
.3 Inspection and adjustment
.4 Checking of condition
.5 Replacement (including lubricants)
.6 Performance test
Pos.
00
12
14
20
21
22
24
31
32

Text
Burner suspension
Ratchet drive
Hydraulic oil
Gearbox
Geared motor, see
separate instruction manual
Drive wheel
Axial bearing
Roller
Link bearing

D = per 8-hour operation

S = weekly
M = monthly
A = yearly
T = see text in instruction manual

.1
A

.2
4A
A

.3

.4

.5

.6
A

A
A

A
A
A
A

A number in front of the letter indicates the frequency of procedure.

For example, 2M = twice a month.

5.1.1 Lubrication
The nature and type of lubricants can be seen in FLS Key to Lubricants.
Gearbox (21), drive wheel (23) and rollers (32)
Feed grease through grease nipple. Grease quantity per nipple: Approx. 10 cm3.
Quality: FLS 7425.
Ratchet drive (12), axial bearing (25) and link bearing (33)
Lubricate ratchet and bearings with grease.
Quality: FLS 7425

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5.1.2 Cleaning
Burner suspension (00)
General cleaning on and around the unit.
Ratchet drive (12)
Remove dirt and old lubricant by means of solar oil and rags.
5.1.6 Performance test
Burner unit (00)
Move all adjusting devices to ensure that their movements are not impeded in any
way.

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APPENDIX I: Burner suspension

01. Rotary kiln
02. Kiln hood
03. Front cross beam
04. Cross beams for rail suspension
05. Burner carriage
06. Supporting beam
07. Cross girder
08. Burner lance carriage
09. Travel rails
10. Burner
11. Clinker cooler

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APPENDIX II: Carriage

06. Supporting beam
07. Cross girder
12. Ratchet drive
13. Rear suspension frame
14. Hydraulic pump
15. Cross member
16. Hydraulic cylinder
17. Lock nut
19. Front suspension frame
20. Hexagonal shaft end
21. Gearbox
22. Geared motor

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II

15

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APPENDIX III: Carriage, sectional view

14. Hydraulic pump
16. Hydraulic cylinder
17. Lock nut
18. Hydraulic pipework
19. Front suspension frame
20. Hexagonal shaft end
21. Gearbox
22. Geared motor
23. Drive wheel
24. Guide pin for axial bearing
25. Axial bearing
26. Movable cross frame
27. Cross pin
28. Locking block
29. Handle for cross frame
30. Locking plates
31. Rail
32. Roller
33. Link bearing
34. Safety pin
35. Stop blocks

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III

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