INSTRUCTION MANUAL .

SF COOLER 70001622-1

Hydraulic equipment for movement of

drives

Installation, operation and maintenance

Water cooler. Combined servo/boost pump
Oil type VG46

In text, reference is made to manuals etc.:

Hydraulic installations 19871

Storage of hydraulic cylinders 36111

VIGERSLEV ALLÉ 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 INFORMATION 4

2. CONSTRUCTION AND OPERATING PRINCIPLE 4

3. INSTALLATION 9

4. OPERATION 10

5. MAINTENANCE 25

6. REMEDIAL ACTION 30

7. APPENDICES 39
 70001622-1 3

APPENDICES:

Diagram, main pump I and stand-by pump I

Diagram, other main pumps II

Cylinders with flushing valves and shuttle system III

Tank and conditioning circuit IV

Switchover system V

Pump unit VI

The diagrams shown are generic and for reference only. For
job specific diagrams, see the manual from the supplier

Edited by: OGr Proof reading: Oct 04 Pages: 51

Approved by: TMF Translated by: JaRG Checked by: LBJ MGN code: 3A100
4 70001622-1
NOTE!
The present instruction manual is concerned with the situations which,
according to the experience of FLS, are the most likely to occur. An
exhaustive enumeration of all conceivable situations which may occur
during the erection, operation and maintenance of the cooler cannot be
provided.

Consequently, if a situation should arise, the occurrence of which is not

foreseen in the instruction manual, and which the operator is/or feels
unable to handle, we would recommend that FLS is contacted without
undue delay for advice on appropriate action.

1. GENERAL INFORMATION
The frames of the cooler are moved backward and forward by means
of the electro-hydraulic equipment.

2. CONSTRUCTION AND OPERATING PRINCIPLE

See Appendices I, II, III and V.

2.1 Hydraulic pumps

The equipment consists of hydraulic cylinders with through-going
piston rods and pump units, connected to a common oil tank. The
pump station has a local control panel featuring a programmable logic
controller.

Each pump unit consists of a main pump - Appendix I (315) - with a

built-on proportional valve and a combined servo- and boost pump on
the same shaft. During operation, only one pump unit is running for
each frame, whereas the last unit serves as a backup unit for the
normal pumps in active operation.
All pumps are identical, being operated at a speed depending on the
frequency 50 or 60 HZ.
The main pump (315) - Appendix I - of the pump units is an electri-
cally-operated axial piston pump featuring variable output and reversi-
bility of pump direction. The output of the pump and the direction in
which the pump is operated are determined by the position of a
"rocker cam”, the setting - “angling” - of which will determine the oil
flow rate of the pump and whether the pump is to be utilized for port A
or B.
The main pump and cylinders – Appendices I, II and III - operate in
closed circuits for reversing the direction of movement of the pistons
in the cylinders in response to a change in the direction of pumping.
The output of the main pumps is controlled by the PLC controller, via
the proportional valves of the pumps.
 70001622-1 5

Two linear transducers are fitted on each of the movable frames; they
continuously provide the PLC unit with specific positional data.

Based upon the positional indications of the cylinders, the PLC unit re-
leases a signal to the main pumps when a reversal in the direction of
pumping, and thus the directional movement of the piston, is to be
made.

Ball valves (605+655) are fitted between the pumps and cylinders to
shut off the oil supply from a pump and to initiate the oil flow from
the standby pump.

The ball valves (605+655) are equipped with micro switches so that
the screen of the control panel will indicate which connections are
open and can be started.

Frame
All the frames are identical, but must be operated independently of
one another. A frame is driven by cylinders (01) connected in a row.
One of the position transducers continuously feeds a signal to the
PLC unit to determine the exact timing for the reversal of movement.
The second transducer is used as a back-up unit and for alarm trip-
ping if there is no movement of the frame.

The total stroke length of the cylinders is 200 mm, of which only 150
mm is normally required by the frame, thus leaving 25 mm at either
end as an oil cushion and as a reserve for conveyance. Therefore,
shock impacts in the system resulting from the piston striking against
the ends of the cylinder will not occur.

When the transducer indicates that, for example, 15 mm of the

movement of 150 mm remains to be completed, the PLC unit will be-
gin, via the proportional control valve, to slow down the cylinder; the
output of the pump will bring the frame to a standstill, by the “rocker
cam” being turned to neutral position while completing the remaining
15 mm.

However, the "rocker cam" of the pump does not stop at the zero-
point, but continues in the same direction until its position is reversed,
causing oil to be pumped in the opposite direction.
This will lead to a change in the direction of movement of the cylin-
ders, causing them to accelerate to the same velocity in the opposite
direction.
The cylinders have through-going piston rods, ensuring an identi-
cal velocity of the conveying and return stroke of the frame.
6 70001622-1
The forces required to push the clinker forward and to pull the frame
backward through the clinker layer are not of equal strength.
Therefore, there will be a slight difference in the pressure in the two
directions.

2.2 Oil conditioning - booster pump, servo pump and shuttle valve
As previously noted, the main pumps and cylinders operate in closed
circuits, and this means that it is basically the same oil which is being
circulated in the individual circuits.

The two pipelines carrying the oil for all the cylinders of a frame are
equipped – after the last cylinder - with a valve block with built-on
shuttle valve (1130). See Appendix III.
To prevent the same oil from being circulated from the pump to
the cylinders (01), the pipe system is equipped with a shuttle
valve. The shuttle valve is governed by the pressure differential
between the input flow and the return flow in the main circuit.

When the differential pressure of the movement exceeds a level

of approximately 14 bar, the shuttle valve (1130) – see Appendix III -
opens and directs oil to the tank via the double filter (150) and the oil
cooler (140), see Appendix I.
The pressure on the low-pressure side is then determined by the
booster pump and the pressure loss in the pipelines.
From the tank, fresh oil is constantly fed to the circuits via the internal
booster pump in the main pump (315).
The quantity of oil which flows to the tank via the shuttle valve is thus
replaced by oil from the booster pump. The booster pump also re-
places oil drained from the main pump.

Thus, the booster pump ensures that a sufficient oil volume is con-
stantly maintained on the suction side of the main pump. To further
ensure that this is the case, a hydraulic accumulator (460) is incorpo-
rated between the booster pump and main pump to ensure that the
necessary quantity of oil is present in case of rapid flow variations.

The additional booster oil for the main pumps is ensured by an inter-
nal pressure relief valve set at 35 bar.

To maintain the quality of the oil, the oil is continuously cleaned and
cooled.
The return oil from the shuttle valve (1130) and the drained oil from
the main pumps are passed through the filter (150).

The circulation pump (200) see appendix I is used to condition the oil
(heat, cool and filter the oil) and it supplies the main pumps with oil.
 70001622-1 7

This oil helps secure the oil supply to the bearings of the main pumps
and it fills up the pumps prior to start up.

When the main pumps are at standstill and with the extra pump (200)
running, the oil will flow through filter (165), through all pumps and
through to the drain line and the filters (150), causing the pumps to be
flushed and the oil to be cleaned.
In this way, the oil in the tank can be cleaned, subject to utilization of
the filters (165) and (150).
When heating of the oil is necessary, use the circulation pump (200)
for heating by closing the electrically operated pressure relief valve
(210). This introduces a pressure drop causing the oil to be heated.
See instruction manual for electrical equipment. Pump (200) can thus
be used for heating, but only when the main pumps are stopped.
Filtration of the oil is done simultaneously through the filters (150) +
(165).
Therefore, the pump (200) should remain in operation during any kiln
shutdown of short duration in order to maintain the oil temperature at
a high level, while, simultaneously, cleaning of the oil is being carried
out.

NOTE!
If any parts of the servo- or booster oil circuit require dismantling, it will
be necessary to relieve the accumulator pressure prior to dismantling.
Normally, the pressure will be eliminated quickly through the accumu-
lator safety block, but checking is necessary on the pressure gauge
(455).

2.3 Servo oil

As mentioned in sub-section 2.2, the proportional control valve re-
ceives servo oil from the combined servo- and boost oil pump of the
main pump at a pressure of 35 bar preset on an internal valve built
into the pump. Readings of this servo pressure can be obtained on
pressure gauge (455). The proportional control valve governs the
”rocker cam” of the main pump; the position of the rocker cam will de-
termine the pump output as well as the direction of oil flow to A or B.
The preset pressure of the oil for the proportional control valve must
ensure that the operating speed of the valve is sufficient. Surplus
servo oil is directed to the booster system.
NOTE!
In case of necessity to dismantle any parts of the booster or servo
oil circuit, the accumulator pressure must be relieved before
such action is taken.
Normally, the pressure will be eliminated quickly through the accumu-
lator safety block, but checking is necessary on the pressure gauge
(455).
8 70001622-1

2.4 Alarms and interlocks

See Appendices I, II and IV.
Level switch (125) will trip first a warning alarm and later it will stop the
electric motors if the oil level is too low. The oil level can be visually
inspected through level glass (120)
The switch (130) features built-in temperature monitoring.
The temperature transmitter will prevent the motors from being
started if the oil temperature is too low and it will trip first a warn-
ing alarm and later stop the pump station if the oil temperature is
too high. See also sub-section 4.2.2.
The function of pressure switch (490) is to check that a sufficient
pressure is maintained in the booster system. The main pump stops in
case of a pressure drop to level below 15 bar. See instruction manual
for electrical equipment.
The booster pressure can be observed on pressure gauge (455).
The ball valves ahead of the pumps are equipped with switches for in-
terlocking the pump motors.
All filters are equipped with differential pressure controllers for tripping
of alarm in case of clogged filters.

At the bottom of the tank there is a drain valve for collecting conden-
sation, if any. When the plant is in normal operation, the oil tempera-
ture will be high enough to prevent condensation, but collection of
condensation in the tank may occur during the periods when the plant
is at standstill.
The tank is equipped with a hand pump (690) which can be connected
to the pipe sections towards the cylinders so that the latter can be
moved manually when the pump station is inoperative, for example in
connection with maintenance work involving the movable frames of
the cooler.
Ball valves (605) and (655) are located between pumps and cylinders
for shutting-off. The ball valves are also used for switching the opera-
tion to the standby pump. The ball valves feature micro switches for
recording the position – shown on display in control panel – and thus
for checking of switchover prior to starting of standby pump.
 70001622-1 9

3. INSTALLATION
Installation to be carried out in accordance with drawings and pipe
diagrams and otherwise as directed in the instruction manual 19871,
HYDRAULIC PLANTS.

However, we normally recommend that pipe bends be used whereas

the use of angles must be avoided.

The hydraulic pump and motor number 1 (nearest the

tank on the pump station) must be connected to the cyl-
inders on the left-hand side of the cooler (viewed in di-
rection towards the cooler outlet). The port A from the
pump must be connected to the cylinders so that the
piston is moving in direction towards the cooler outlet
when oil is pumped from port A.

Place screwed connections for aeration in the pipes

situated at the highest locations. See sub-section 5.4.

Check that the cylinder ports of the cylinders for the

single frames are connected to the same pipe connec-
tion from the pump.

The pump station is normally shipped in a container and it must not be

removed from the container until installation of unit at site is imminent. If
the pump station is shipped in the unpacked condition (which is some-
times the case for certain destinations), the unit must be kept in a dry
place and must be protected against dust in a store room up to the point
of installation. This also applies for the electrical cabinet and pipes and
loose fittings.

Do not remove the plugs in the cylinders and do not connect them to
the pipe system until the system has been flushed and is ready to be
pressure tested. Otherwise there is a risk of contaminating the cylin-
ders.
10 70001622-1
4. OPERATION

4.1 Initial start-up procedure

4.1.1 Hydraulic oil
The additives in the hydraulic oil may cause skin problems, and se-
vere eye problems. The precautionary measures indicated on the
data sheets from the oil supplier must be observed.
Oil quality: FLS Mat. No. 7025. Corresponding to ISO
VG 46.
This oil grade is recommended for operation with the oil
temperature maintained within the range 55-60° C. If a
lighter or heavier type of oil is deemed to be more ap-
propriate, the oil temperature must be adapted to the
new oil type. See data for pump in supplier’s manual.
Data and settings in suppliers manual always overrule
data or settings in this manual.
Oil filling must only be done using the pump (200) as follows:
Check that hose and quick release connections are clean.
The hose is located in an enclosed metal tube at the tank.
Establish a hose connection between the suction side of pump
(200) and the oil drum.
Place the free end of the hose in the barrel containing the fresh oil.
Close all suction valves on the tank and supporting structure. Place a
bucket under the drain valve at the bottom of the tank and open it,
drain any accumulated water.
Close all valves (311) leading into the main pumps.
Make sure that 3-way ball valve (190) is shutting of suction line from
the tank.
Jog-start pump (200) in order to check the direction of rotation.
Start the filling operation and stop the pump when suction is done
from an empty barrel; the sounds emitted will clearly indicate whether
the barrel is empty.

Fill the tank to the upper mark on the oil level glass (120).

Stop the pump (200) and disconnect the filling hose.

Position the 3-way ball valve (190) so that pump (200) is being sup-
plied with oil from the tank.
 70001622-1 11

Attentions is drawn to the fact that fresh oil is NOT clean,

and therefore, the pump (200) must be started and remain
in operation for some time, since this will cause the oil to
be returned through the filters and cleaned prior to any
transmission of the oil to the cylinders. Filtration of the oil
also takes place by circulating it through the main pumps,
but use of the filter (165) should be avoided at this point so
valves (311) are to remain closed until the pump (200) and
the filters (150) have removed impurities from the new oil.
See details in subsequent section.

4.1.2 Cleaning of pipe system

(See instruction manual 19871 for initial preparation of hydraulic
plants).
The service life and reliability of hydraulic systems depend entirely on
the cleanliness of the system.

It is of the utmost importance to ensure absolute cleanliness of

the oil. It is essential to avoid impurities of any kind in the pipelines
and in any of the components. Therefore, the system must be flushed
out before it is connected to the pump station and the hydraulic cylin-
ders.

Normally, this level of cleanliness can only be achieved by using a

special filter pump equipped with the necessary equipment for ensur-
ing rapid pressure and flow variations in order to dislodge impurities
and rust in the pipe system (flushing system). This flushing proce-
dure is strongly recommended by FLS.
If a “flushing” unit cannot be made available, the pump station is de-
signed so that the standby pump can be used to flush out the pipes by
means of a special filter which is fitted ahead of the standby pump;
this filter must be disconnected on completion of the flushing proce-
dure. However FLS can not guaranty that this solution removes all im-
purities.

Fresh oil does not have the necessary degree of cleanliness, and,
therefore, the oil must be cleaned after being charged to the system.

The circulation pump (200) is used to clean the oil in the tank and the
equipment on the pump station by diverting the oil through the filter
(150). First, the oil is heated by maintaining the heating circuit – valve
(210) activated – in operation until the oil temperature has been raised
to the highest possible level (preferably 60ºC). With the valves (311) in
closed position, to prevent contaminated oil from reaching the main
12 70001622-1
pumps, there will be a pressure drop across the valve (210) and (133)
until the rise in the oil temperature has been halted.

The pump must be maintained in operation until the system has been
effectively cleaned. Minimum 24 hours. Measuring of cleanliness level
can be done using special equipment or, in this situation, based on
the observation that constant pressure drops across the filters have
been achieved.
Requirements in terms of cleanliness: ISO 4406, class 18/16/13. Oil
samples must be taken during the flushing process and analyzed until
the required cleanliness has been achieved.

When the filtration process is completed the flushing can begin. Start
with cold oil app. 20Cº and let it during the flushing process heat up to
the highest possible temperature (preferably 60 Cº)

Open all valves (311) ensuring clean and warm oil to all main pumps,
but keeping all valves (655) closed ensuring isolation of the still con-
taminated piping system.

Flushing to be done at least 24 hours. Oil samples must be taken dur-

ing the flushing process and analyzed until the required cleanliness
have been achieved.

Flushing of the pipe systems must be done as follows: The standby

pump forces oil out through the B-port and all the way through the
pipe system and back via the A-port, first on the valves (605) and then
in route to the pump through the pressure filter (700) – see suppliers
diagram - so that purified oil is returned to the pump.

This method must only be used when the pipes are clean, i.e. pipes:
“Precision Steel Tubes” (phosphated and oiled) as well as cleaned
with clean rags/dry compressed air – N². Rust in pipes must not occur.
The pipes must be protected against contamination and corrosion be-
fore and during installation.

NOTE!
The plugs in the cylinders must remain fitted until flushing of the pipe-
lines has been carried out.

The pump will sustain severe damage if contaminated

oil – not subjected to filtration – is re-circulated to the
pump.

Therefore, the standby pump must be connected to the

check valves (715) and (716) and the pump must be an-
 70001622-1 13

gled so that the oil flow from the pump is directed to

the B-port.

This is ensured by:

- Attaching the hose connected to the B port on the stand-by pump

to the check valve (715) to ensure oil passage only to the pipes
and not to the pump.
- Attaching the hose connected to the A port on the stand-by pump
to the check valve (716) to ensure that oil entering the pump has
passed the pressure filter (700). See diagram in suppliers manual.
- Note that the pump station is supplied with the hoses connected
for flushing, but connections should be checked anyway.

The next step involves selection of the frame and pipe system which
are to be flushed first.
All ball valves (655) must be closed.

The ball valves (1150) on Appendix III must be connected to the two
hoses (1020) and (1021) which in term will be connected to the cylin-
ders (01) at the subsequent operational stage of the plant. The hoses
(1060) and (1061) near the shuttle valve must be connected to the ball
valve (1151) so that all oil is forced back to the pump, in order to pre-
vent contaminated oil from reaching the shuttle valve (1130). In the
beginning all ball valves (1150) must be closed, and the valve (1151)
must be open. Please refer to Appendix III.

The pump (200) must be started and the ball valves (311) must be
open to ensure lubrication of the main pumps and this will ensure that
the pumps are filled with oil.

To determine whether the angling of the standby pump is correct, the

pump must first be jog-started with closed ball valves (1125) and the
rotational direction of the motor must be checked.
If noise is emitted by the pumps at subsequent stage when they be-
come operational, a check is needed to determine that they are filled
with oil, accompanied by a cautious relaxation of the drain ports until
outflow of oil is observed.

The ball valves (1125) must be kept closed, and subsequently the
pump is started without angling, with the pump being cautiously an-
gled until it has been definitely established at which side of the pump
angling is to take place. This can be determined by touching the
hoses, or by checking the pressure gauges (620) and (670) when the
pump delivers oil to port B. This must be done with a low maximum
pressure which is adjusted on the local control panel.
14 70001622-1

The pump can then be started without angling, with subsequent open-
ing of the ball valves (1125) in direction from the standby pump to the
pipe section which is to be flushed, thereby initiating the flushing pro-
cedure. The rate of angling of the pump is slowly increased towards
the maximum limit while the oil pressure and filter are closely moni-
tored; after the oil has been cleaned, the ball valves (1150) at the cyl-
inders must be opened one by one, starting with the cylinder in imme-
diate proximity of the shuttle valve. When the first valve (1150) has
been opened the valve (1151) at the shuttle valve must be closed.
Only one ball valve (1150) is to be open at any one time – however,
see information subsequently provided in this section. After the oil has
been cleaned, the ball valve (1150) is cautiously opened at the next
cylinder from the shuttle valve, and (1150) nearest the shuttle valve is
cautiously closed. The procedure is repeated for the hoses for all the
cylinders in a row, with only one hose opened at any one time and in
the exact sequence from the shuttle valve.
Now the pipes must be pressure tested, open all valves (1150) and
(1151) at the shuttle valve (1130), close the valve (1125) in the A line
only. NOTE: This is important only close valve in A-line, when
pressure testing all pipes will then have pressure except the line
from valve (1125) to the flushing filter at the pump station. Pres-
sure test the lines up to 300 bar and the pump must be angled to
same side as when flushing, port B (VERY IMPOTRTANT). Otherwise
only the hose from the A port will be pressure tested. Throughout this
process, one person must be ready at the emergency stop so the
pump can be stopped immediately in case of severe leakage from a
pipe joint. CAUTION, wear protective glasses and keep unauthorized
personnel away from the pipes. When pressure testing is being
conducted, the operating personnel must be a safe distance away
from the pipe system to eliminate the risk of injuries to skin and/or
eyes.
The remaining part of the pipe system will be pressure tested later.
Having achieved effective cleaning of the pipes and oil, the pump is
stopped and the ball valves (1125), (1151) and (1150) are closed to
minimize spillage of oil when the coupling of the two hoses at the shut-
tle valve is dismantled and the hoses are connected to the shuttle
valve. See Appendix III.

Subsequently, the pump is re-started without angling, (remember to

adjust the pressure down form the 300 bar used for pressure testing)
and the ball valves (1125) and (1135) are opened along with the ball
valve (1150) nearest the shuttle valve, and subsequently the pump is
slowly angled in the same sideways direction as before, until the
maximum rate of angling has been achieved. After the pipes have
been cleaned, the ball valve (1150) is cautiously closed until the pres-
sure drop across the ball valve is sufficient to ensure activation of the
 70001622-1 15

shuttle valve and simultaneous flushing of its pipeline. This can be de-
tected by feeling the temperature rising in the drain pipe.

The procedure must be repeated for the other pipe systems.

Prior to shipment, the local control panel has been set for a pressure
of approximately 50 bar, and this pressure may have to be increased
during the flushing procedure when the entire oil flow is to pass across
one ball valve (1150). At a pressure drop above 50 bar, two ball
valves must be kept open simultaneously. At a pressure drop above
100 bar, the oil is heated and the motor is severely strained; as a con-
sequence hereof, high pressure drops should be of short duration. For
this reason, the pressure compensation set point of the pump must be
approximately 120 bar during the entire flushing procedure.
This limitation of pressure is of even more importance
in order to protect the filter cartridge against rupture in
the event of a sudden blockage, entailing risk of severe
damage to the pump!
During the flushing process, the pressure drop across the flushing fil-
ter must be strictly monitored and the filter cartridge must be replaced
immediately in case of any signs of obstruction.
During the flushing process, the oil temperature must always be main-
tained within the range 55-60º C to ensure at the same time a low
viscosity of the oil for optimizing the cleaning process.
The return filters (150) must be continuously monitored and a re-
placement of the filters will be necessary if an alarm indicating ob-
struction of the filters is tripped. See Appendix I.

Maximum cleaning efficiency is achieved if the high oil temperature is

maintained, accompanied by simultaneous maximum supply of oil
from the pump. The latter condition is necessary to generate effective
flow of the oil in the pipes, ensuring entrainment of particles. During
flushing operations, the oil pressure must be monitored on the pres-
sure gauges and the temperatures by feeling on the pipes.

After flushing of all drives, the hoses from the stand-by pump must be
disconnected from the check valves and attached to the foreseen
joints with metal blind plugs in. The blind plugs are to be used for the
check valves. Please observe strict discipline to avoid contaminating
the now clean system.

The pipe systems have now been cleaned and the hoses can be con-
nected to the cylinders; always ensure that these connections have
been cleaned prior to assembly. The ball valves (1125) must be
closed.
16 70001622-1
The remaining pressure test of A-lines from the pump station to ball
valves (1125) can be done now. They too should be pressure tested
to 300 bar. Throughout this process, one person must be ready at the
emergency stop so the pump can be stopped immediately in case of
severe leakage from a pipe joint. CAUTION, wear protective glasses
and keep unauthorized personnel away from the pipes. When pres-
sure testing is being conducted, the operating personnel must be a
safe distance away from the pipe system to eliminate the risk of inju-
ries to skin and/or eyes.

If it becomes necessary to start up the main pumps before the frames

can be put into operation, this must be done with the ball valves
(1125) closed and without any angling of the pumps.

4.1.3 Initial starting to be effected from the local control panel.

Pump units and the entire pump station have been tested prior to
shipment to site. The electrical control panel has also been tested.

4.1.4 Oil filling

See Appendices I, II and IV.
Oil filling must only be done using the filling pump (200) at filters
(150). Make sure ball valve (190) is positioned so the suction side of
the pump (200) is connected to the suction hose and not to the tank.
The pump must be jog-started to check the direction of rotation.
Stop the pump when suction is done from an empty barrel; the sounds
emitted will clearly indicate when the barrel is empty.
Fill the tank to the upper mark on the oil level glass.
On completion of the oil filling procedure, the valve (190) must direct
the tank to the suction side of pump (200). Pump (200) must be
started and kept running for minimum 24 hours, where it will occa-
sionally be involved in the heating of oil but at all times involved in the
cleaning of oil by directing it through the filters (150).
See sub-section 4.1.1.
The same procedure is used for subsequent oil changes, for in-
stance in connection with kiln shutdown, or for major replace-
ments of the oil, e.g. due to ruptured hose(s).
In connection with minor refilling operations, during normal op-
eration, all ball valves (311) must be temporarily closed to prevent
air from entering the main pumps during filling operation. Clean-
ing of the oil is effected by means of the filters (150).

4.1.5 Start-up
a) Check that all suction valves (430) are open.
b) The cylinders must not be connected to the frame at this point in
time but the cylinders must be supported to allow them to move
freely.
 70001622-1 17

Alternatively, the movement of the frame has already been checked

by means of jacks or a hoist, which means that it will be perfectly safe
to connect the cylinders. Also, it must be checked that all the cylinders
in a drive row are placed in the same position when they are con-
nected to the frame, i.e. with simultaneous presence of the pistons at
the top and bottom.

The pumps must not be started unless they are filled

with oil.
c) Set the pressure limiter at 50 bar on the control cabinet.
d) Start the pump motors momentarily and check the direction of ro-
tation. This must be done in consultation with the supervisor of the
electrical installation and the rocker cam must be in 0-position,
meaning no flow to cylinders.

e) The stop limits for the movement of the cylinder must be set as
indicated below before the pump units are started, viz.:
115 mm FORWARD STOP
40 mm REVERSE STOP

Important!
Prior to operating the frames with the pump units, the move-
ment of the frame must be checked by means of tackles or similar
equipment, i.e. 150 mm + 25 mm at both ends of the stroke.
If the system is flushed and the cylinders are connected the hand
pump (690) may advantageously be used to perform the checking.
Cleaning MUST be carried out before the connections are estab-
lished.
It must be possible to move the frames at a low pressure (∼30 bar).
The recommended approach involves connecting the hand pump to
the quick-action coupling (685).
It is essential to prevent contaminated oil from reaching the cylin-
ders. Therefore, the oil in the tank must be cleaned before the hand
pump is used.
It should be noted that the frame is placed at an inclination, and, as
a result, its weight will attempt to pull it in downward direction.

The movement can also be checked while the pump station is in

operation, with the pressure relief valves set for a pressure of ap-
proximately 50 bar and with application of a very small oil vol-
ume.
Start the pump and operate it at 10-20% of the rated capacity -
do not exceed this limit. This is done using the PLC control
18 70001622-1
unit. The output capacity of the pump is adjusted on the elec-
trical control panel.
f) Check that the pressure of the servo-/booster pump is 35
bar when the temperature of the oil is normal ~ 60°C. The
oil pressure can be observed on pressure gauge (455).
g) Let the cylinders move back and forth very slowly between
the preset extreme positions. Venting must be done while
the cylinder is working, using the supplied hoses and
screwed connections with T-pieces for the hoses or by re-
laxing the screwed connections situated at the highest loca-
tions until all air has been expelled from the system. This
operation must be repeated until the air content in the oil is
zero.
Some degree of venting is expected to take place through
the shuttle valve. Without any material in the cooler, quite
small oil pressures are necessary to move the frames, and,
therefore, the shuttle valve may not work exactly as in-
tended with replacement of the return oil from the cylinders.
This can be ascertained by touching the pipe connections
relative to the cylinders and the drain line from the shuttle
valve, and it can be monitored via the flow switches (1140).
Adjust the linear transducers in the two extreme positions,
see instruction manual for electrical equipment.
Then adjust the position of the transducer in relation to the
cylinders.
h) Check the circulation pressure on gauge (225). It should not
reach 20 bar which is the set point for pressure relief valve
(215).
i) Maintain the hydraulic system in operation for two hours,
while slowly increasing the operating speed.
Set the thermostatic set points of the cooling circuit for attain-
ment of an oil temperature of approx. 60°C.
j) Check that the speed s/m is correct.
k) Measure the true length of the piston stroke and compare
it to the set point values. Set the length of the normal
stroke as indicated below. Then check that the resulting
stroke length will be 150 mm. This adjustment is done by
cautiously altering the FS and RS values as well as the
braking and acceleration cycles. Be very careful when
altering any braking cycles which will have an impact on
the braking length.
There must be an oil cushion at both ends.
This must be checked at several speed levels, also at the
maximum speed. See sub-section 4.3.1.

25 mm REVERSE STOP
175 mm FORWARD STOP
 70001622-1 19

The stroke length can be increased at subsequent point in time

if enhanced conveying capacity of the cooler is required.
Since the “rocker cam” of the pump has a hysteresis, the pro-
gram itself will make an adjustment of the “forward auto stop”
and “the reverse auto stop” in accordance with the measured
movements.
It will probably be necessary to revise these settings - particu-
larly the acceleration cycles - when corresponding data have
been recorded during normal operation. Data must be recorded
at a normal oil temperature, approximately 60°C.
l) Stop the pumps.
Restart the pumps one by one and on the screen adjust the
pressure limiter setting of the pump at 260 bar, and test it in
both directions against closed valves (1125). This adjustment
must be made at 30-40 % of the maximum oil flow.
Because of localized heating, the duration of setting proce-
dures must not be any longer than is strictly necessary, i.e.
not more than 1-2 minutes. See sub-section 4.7. Pressure
test the remaining part of the pipes (close all valves (1125).
Pressure test with the correct pump for the drive to be done
angling to port A and B (valves (1125) still closed). This
must be done at 260 bar, and subsequently the pressure is
adjusted to 240 bar. Throughout this process, one person
must be on standby so that the pump can be stopped im-
mediately in case of severe leakage from a pipe joint. Cau-
tion, wear protective glasses and keep unauthorized
personnel away from the pipes. As previously noted, a
check must have been done prior to the performance of
pressure test(s) to ensure that the cylinders have been
mounted in exactly the same way, i.e. so that they are at
the top and bottom simultaneously to prevent undue stress
loading of the fittings of the frames.
m) When pressure testing is being conducted, the operating
personnel must be a safe distance away from the pipe sys-
tem to eliminate the risk of injuries to skin and/or eyes.

n) The no-load operation of the pumps (0° angling), i.e. the posi-
tion of the rocker cam inside the pump, must be checked.

Check the adjustments on the pump card. See instructions

from the electrical department. When at standstill, the pumps
will be mechanically placed in a centralized position after being
adjusted by the pump manufacturer. There will be a minor
hysteresis.
20 70001622-1
The adjustment, in its entirety, can be checked, if necessary, by
adjusting the flow in both directions via the pump card, duly re-
cording at this location the exact time for the occurrence of
pressure and movement in the two directions.
Start up slowly by operating the pumps and the frames at
minimum speed, often 3-4 s/m, for one hour while strictly
monitoring the service pressures and the general state of
the cooler. See also instruction manual outlining the guide-
lines for erection. Subsequently, the speed can, gradually
within a period of one hour, be increased to a level close to
20 s/m, and this level must be maintained for more than 6
hours. Check that drive plates or U profiles are not getting
hot from the friction with the C profiles, this can be felt or
seen from the under grate chamber, correct if necessary.
See erection instruction. Note: this check must only be
done when the cooler is stopped. The stroke lengths and
oil temperatures must be checked at least 3 times. If nec-
essary, adjust the temperature setting for activation and de-
activation of oil cooler. Following a stoppage, the oil filters
should be checked, and should normally be replaced, unless
this has already been done after the flushing operation. From
the shuttle valve, about 2 liters of oil must be extracted,
since, most often, the pressure differential will be insufficient
for the shuttle valve to be activated in no-load condition, i.e.
there is no replacement of oil.

p) Repeat the venting operation as described in item g.

4.2 Normal remote-operated starting from centralized control panel

4.2.1 Preconditions for remote-controlled starting
The preconditions for starting the frame from a centralized control
panel are as follows:

a) Always ensure that interlocking alarms resulting from the

monitoring of temperatures, oil levels, etc. do not occur.
b) All valve handles must be placed in open position.
c) The electrical control panel must be switched to operation
from the control centre.

Once compliance with these preconditions has been ensured, the

hydraulic plant will be ready for remote-controlled start-up.

4.2.2 Heating
In case the oil temperature is lower than 25°C, the pump station must
be put into operation well ahead of the start-up of cooler operation in
 70001622-1 21

order to ensure that the oil is properly heated so that the oil will have
the viscosity required to make the pumps work.
Heating is done through circulation from pump (200), by forcing the oil
through the pressure relief valves (210) - Appendix IV -. in order to raise
the temperature in situations where the temperature is within the range
5 - 10°C.
It will not be possible to start the main pumps if the oil temperature is
lower than 9°C.
See also the instruction manual for electrical equipment.
4.3 Controlling of frames - starting position for operation
See description in the instruction manual for electrical equipment.
The hydraulic pump is started in no-load condition (0°-angling), its an-
gling being subsequently altered so that the piston of the cylinder is
forced against that end of the cylinder which is furthest away from the
starting point.

4.3.1 Operational description

See description in instruction manual for electrical equipment.
Movement of the frame is maintained within a range of 150 mm
using the following braking points:

I_____I_____I____________________I____I______I_____
0 RS RAS FAS FS 200
RS REVERSE STOP
RAS REVERSE AUTO STOP
FAS FORWARD AUTO STOP
FS FORWARD STOP
From the starting position, movement is started at the velocity
requested by the central control panel or the local control unit.

In connection with the adjustment of transducers and checking of

movements, it may be necessary for the operators assigned to such
tasks to enter the cooler. This involves a risk of the person sustaining
injuries if squeezed/crushed by moving parts. Therefore, any such op-
eration must be strictly monitored by the plant supervisors
and a heightened state of alertness must be ensured so that the in-
stallation can be shut down immediately in case of an emergency.

The pistons of the cylinders move forward at the preset velocity until
they reach the point FAS. The angling of the pump is then adjusted to
0° within the duration of the braking length to the point FS.

After the "rocker cam " has reached 0-position (0° pump angle), the oil
flow is diverted to port B by moving the "rocker cam " to the opposite
22 70001622-1
side. This is done within the time period allowed for "Reverse Up
Ramp".

Fig. 1
Oil flow from port A STOP AUTO FORWARD
forward is reached

Ramping up Ramping down

reverse reverse
STOP reverse STOP REVERSE
STOP forward
Time

Ramping up Ramping down

forward forward

Oil flow from port B STOP AUTO REVERSE

reverse is reached

The pistons of the cylinders then move forward again and the process
will continue as described.

The positions FAS and RAS are calculated by the PLC unit on the ba-
sis of the applied set points for RS and FS and the current values of
braking and acceleration cycles and the pump capacities.

In this connection, the PLC unit is programmed for monitoring stroke

lengths and grate speeds and to adjust the pump capacities and FAS-
RAS.

Also, the pumps will be swiftly directed towards the ZERO point in
case the RS and FS parameters are exceeded.

The values below must be applied as default set points for the posi-
tions and accelerations, but they can be adjusted in the PLC unit:

RS = 25 mm
FS = 175 mm
Acceleration and braking cycles must be set for 250 ms.

Adjustments of braking cycles as well as acceleration cycles can be

done in the PLC unit. For example, they may be increased to 300 and
350 m/s if the maximum capacity of the pump units is not fully utilized.
Always remember to increase the braking cycles in small steps in or-
der to prevent the cylinder from striking against the bottom.

It is essential to ensure that the limits for the forward and reverse
movement are correctly adjusted in relation to one another, as
illustrated in Fig. 1.
 70001622-1 23

A fine adjustment is done on the basis of movements registered

during normal operation.
In particular, an adjustment of the acceleration cycles will often be
necessary since they will determine how quickly, and especially the
impact with which, the position of the shuttle valve at the cylinders
will be changed.

When making the adjustment, it is essential to ensure that the

movement of 150 mm is obtained during normal operation and
that the risk of the cylinder "hitting the bottom" - when the frame
is operated at the maximum speed - is eliminated. In case this is
deemed to involve major complications, do not hesitate to contact
FLS to allow minor modifications of the PLC program to be made.

4.4 Pump switching

See description in the instruction manual for electrical equipment.

4.5 Cooling
See Appendix IV.
The oil is continuously cleaned and cooled; to ensure that this is the
case, the pump (200) and the built-in servo- and boost pump of the
main pumps (315) will constantly pump oil through the filters at the in-
take points (165) and (450) of the pumps and from the drain lines to
an oil cooler (140) and the filters (150).
The filters are provided with contamination indicators and alarms in
case of clogging of the filter.
If the oil temperature should rise to a level above 60°C, a water valve
(145) will admit cooling water to the oil cooler (140).
If, despite such precautionary measures, the oil temperature should
rise to 65°C, an alarm for high oil temperature is activated. This is a
pre warning to indicate that the fan has not been started or that the
thermostatic valve is improperly adjusted. In case of a further rise in
the temperature to 70°C, the pump station is cut out via the local con-
trol panel. The temperature settings can also be adjusted in the con-
trol panel.

4.6 Oil heating without starting the hydraulic piston movement

See description in instruction manual for electrical equipment.

4.6.1 Remote control of heat-up operation

The oil temperature must be maintained within the range 18°-25°C as
described in sub-section 4.2.2. Heat-up operation to be started at
stage where it is foreseeable that the operation of the frames will be
initiated in a matter of hours, thus ensuring that the oil has the appro-
priate service temperature (>20°C) when the start command is given.
 24 70001622-1

4.7 Oil pressure

The system incorporates a maximum pressure setting which is set for
the maximum allowable operating pressure which must prevent se-
vere damage to mechanical components, e.g. the beams or frame of
the cooler, if the maximum pressure output (> 300 bar) is applied in an
unfavorable operating environment. Such pressure limitation takes the
form of an electronic pressure compensation, which means that if the
pump is working at maximum pressure, it will execute pressure com-
pensation by allowing the “rocker cam” to drift towards “0” so that it will
only just be possible to maintain the maximum pressure.
Hence, the pump will be stopped with an alarm for “pump card failure”.
Therefore, any subsequent adjustments must take the form of minor
oil flow adjustments in order to avoid a cut-out of the pump.
When pressure tests are being conducted, it is essential to ensure
that operating personnel is at a safe distance away from the pipe
system to eliminate any risk of injuries to skin and/or eyes.
The maximum pressure of the pumps can be set in an menu on the
screen of the local control cabinet and tested by allowing the pumps,
one by one, to operate against a closed valve (1125). Switchover must
be done with the electrical control unit in the LOCAL mode. Adjust-
ment must be done at an oil flow of less than 50%. Flow rate to be set
with the control cabinet in MANUAL mode.
The maximum pump pressure can also be set by allowing the pistons
of the cylinders to move gently to the bottom, and then to let the pump
try to push the piston further inward through modifications in the elec-
trical control system of the pump. See sub-section 4.1.4 for manual
control of oil flow.
An alternative approach involves dismantling of one of the hose con-
nections between the pump and the pipe system, using plugs to close
the openings in the pump and the pipe system. The maximum pump
pressure, “pressure compensation”, is then set in a menu on the
screen of the local control cabinet and subsequently tested.
Always remember that the pump is angled; otherwise, the flow rate will
so small that it will not be possible to achieve the maximum pressure.
The booster pressure can be adjusted internally on the pump See
suppliers instruction.
The servo- and boost pressure has been fixed adjusted for 35 bar and
should not need further adjustment.

4.8 Manual operation

Once a start command for local control has been given from the cen-
tral control room, the drives can be moved backward and forward via
the local control cabinet at the desired velocities. See description in
the instruction manual for electrical equipment.
 70001622-1 25

5. MAINTENANCE
The cylinders and pump station must be inspected and maintained in
strict accordance with the instructions given by the equipment sup-
plier.

So, in the following, attention is focused primarily on conditions which

are deemed most likely to affect the operation of hydraulic cooler
drives.

5.1 Daily checks

Attention must be given to the risks involved in case of ignition of
spilled oil.

• Check, on a regular daily basis, that the shuttle line is in operation

by physically touching the drain pipe in order to determine whether
its temperature matches the temperature of the pipes for the cylin-
ders. The function of the drain line is supervised by an electrical
flow switch (1140) see Appendix III, which will give an alarm. The
shuttle valves (1130) and internal valves (1135) must then be
checked at first convenient stop

The temperature of both pipes to and from the cylinders must be high;
otherwise, only one unit will be drained and the same oil will be present
in the cylinder of the second unit all the time. Contact FLS if the oppo-
site is ascertained to be the case during normal operation of the plant.

This phenomenon can be observed during no-load operation and at the

start-up stage until the level of material inside the cooler has reached
the point where an oil pressure has been built up.

• Check for any leakage from the cylinders and assemblies inside
the cooler. Use the observation ports in cooler wall to check this.
• Check for any leakage from the screwed connections.
• Check hoses.
• Check for any leakage from the pump station. Re-tighten
assembly points in case of leakage.
• Check the operating pressure. In case of abnormally high or very
low pressures, contact the operating and maintenance personnel
for information as to whether the abnormal pressure is due
to specific operating conditions, e.g. very coarse clinker in the
cooler.
• Check oil temperature and systems for oil cooler.
• Check the oil level and check for any foam formation in tank.
26 70001622-1
5.2 Weekly checks
Attention must be given to the risks involved in case of ignition of
spilled oil.
• Check for any indication of filter contamination. Replacement of
filter cartridge can take place in connection with forthcoming shut-
down. See instruction manual for filter (5.5).
• The filter elements in filter (150) can be replaced one at a time by
directing the oil to the other filter element by operating the handle
on the filter house
• Check that there is no oil flow across the non-return valve
(215), since this would prevent the oil from being cooled and
cleaned in (150). This can be checked by touching the valve
house to determine whether its external temperature is high.
• Check the function of the oil cooler by physically touching the oil
pipes, and check the oil temperature.
• Check the movement of the grate, 150 mm on the display unit and
by observing the cylinders.

5.3 Major overhauls

Over time, the oil will undergo deterioration due to contamination, age-
ing, and build-up of micro particles. Therefore, the oil must be ana-
lyzed every 6 months. Samples of minimum 1 liter of oil must be ex-
tracted during operation after extraction of minimum 0.5 liter which
must be disposed of. Use clean bottles or flush the bottles with oil until
they have the necessary level of cleanliness.

Clean the pipes and hoses thoroughly and check the parts for any
signs of wear. Damaged or worn parts must be replaced and pro-
tected against future wear. For example, by preventing the cooling air
fan from blowing dust at a high velocity against the components.

Clean the shuttle valve block.

It should be noted that in connection with the inspection and mainte-

nance of the cylinders and the pipe system inside the cooler, the
worker(s) involved in the operation may sustain injury if caught be-
tween the mechanical parts of the cooler in case the hydraulic installa-
tion is inadvertently started. To prevent this from happening, the ball
valves (1125) must be closed and locked out.

If a leakage check of the assemblies inside the cooler is to be con-

ducted, the worker(s) assigned to the task may have to crawl into the
cooler, and this will involve a risk of injuries because of high-pressure
oil and/or ignition. Therefore, any inspection which is to be made while
the pump station is in operation must take place subject to external
supervision and strict control procedures, and safety equipment for
combating any fire caused by the ignition of oil must be held available.
 70001622-1 27

Note: Due to safety reasons no personnel must enter the cooler when
the flame is ignited or being ignited in the pyroprocessing sys-
tem. Before personnel enter the machine ensure that there is
enough oxygen in the air and that no toxic fumes exist. Normal
lock out procedures for electrically equipment must be followed.
Also make sure that all valves (1125) see Appendix III are closed
before any work is done inside the cooler

5.4 Oil change

Attention must be given to the risks involved in case of ignition of
spilled oil.
Empty the tank while the oil is still warm by allowing it to flow out
through the bottom drain, or pump it out using the circulation pump
(200) and the hose (187) connected to the output end of the pump.
Add fresh oil up to a level which is approximately 15 cm above the
suction point of the pumps, and flush out the system with the fresh oil.
Drain all oil from pipes and tank. If the drained oil is still contaminated,
the tank must be cleaned. This may be done by adding another 50-
100 litres in order to remove contaminants from the tank.
If the mentioned measures do not have the desired effect, the tank
must be cleaned using clean rags; avoid any use of cotton waste or
similar rags which may release fibers. Replace the filter elements.

A dust-free environment must be ensured in the

room when performing the clean-out operation.

If the room is not dust-free when reconditioning of the equipment is to

be carried out, it is prudent practice to dismantle the unit, plug up the
connections and to recondition the equipment in a specialized work-
shop.
Clean oil must always be charged using the circulation pump (200)
and hose (187). The main pumps must not be running while oil is be-
ing charged to the system if the oil level is so low that there is a risk of
air being sucked down into the pumps. See sub-section 4.1.1.
Add fresh oil. Do not mix oils of different types and makes.
The oil must be clean, sourced from a clean barrel. The hoses and
quick couplings (185) and (186) must also be meticulously clean be-
fore they are coupled together.
In case foam is being formed in the tank, the pumps must not be
started until the air has been expelled from the oil, and the oil must be
transparent and clear.
28 70001622-1

The fresh oil must be circulated through the filters (150) by means of
pump (200) for as long as it takes to ensure absolute cleanliness
of the oil before the main pumps are put into operation. See sub-
section 4.1.1.

Venting
Removal of air in the oil at the cylinders must be done through the
shuttle valve block (1130) by inserting hoses in measuring nozzles,
allowing oil foam to be collected in a bucket; see sub-section 4.1.5,
item g.
Be careful to avoid jet flow from the hose.
If the pipes are located above the pump station and the shuttle valve
block, accumulation of air may occur at this location. If so, vent con-
nections must be fitted in the screwed connections.
Vent connections must always be provided at the highest possible
locations. Alternatively, venting can be done by loosening very care-
fully one of the screwed connections.

5.5 Replacement of contaminated filters

Oil filters, see sub-section 5.2.
The filters for drain oil (150) can be replaced one at a
time; this is done by directing the flow to the other
element by operating the valve in the filter house. Any
metal particles or any other foreign objects detected
in the filters or in the filter housings (150) must be in-
vestigated and evaluated, as they might come from the
cylinder seals, or damaged pistons and cylinders. If
dirt is found, the shuttle valves (1130) must also be
opened and cleaned, if necessary.
Check that the system is stopped and de-pressurized. Loosen the fil-
ter housing and replace the filter cartridge. Always ensure that the fil-
ter is properly fastened and check for leakage of the filter during op-
eration.
The filter cartridges must be replaced if an alarm is triggered by the
electrical monitoring unit.
It will not be possible to clean or re-use the filter cartridges. See
data sheet.
Replacement of the circulation filters (165) and the servo-/boost filters
(450) can only be done with the pump and therefore the pump station
stopped. Frequent replacements of the cartridges in (165) and (450)
may be a sign of obstruction in the filters (150), indicating passage of
oil through the non-return valve (215) instead.
 70001622-1 29

NOTE!
Any metal particles or any other foreign objects detected in
the filters or in the filter housings (165) or (450) may origi-
nate from the circulation pump or the servo-/booster pump.
Therefore, an immediate examination of these units must
be carried out.

Air filters
The air filter (115) – Appendix IV - of the tank must be replaced on a
regular annual basis.

5.6 Accumulators
The accumulators will ensure that there will always be enough oil to
effect a change in the operating direction of the pump, thus prevent-
ing the risk of cavitations. The pre-charging pressure of the accumu-
lators must be checked three times a year, in connection with a mi-
nor stoppage or a major, prescheduled shutdown. A kiln shutdown of
short duration can be used to check the performance of the accumu-
lator with the accumulator pre charge kit supplied with the pump sta-
tion. The precharged pressure should be 10 bar. Recharge if neces-
sary.
If damage to the bladder of the accumulator is observed, the stand-
by pump must be used until reconditioning or replacement of the ac-
cumulator has been carried out.

5.7 Cylinders
The spherical plain bearings at each end of the cylinder are maintenance
free type, but must be cleaned and inspected in connection with major
overhauls. See supplier’s documentation. Check also whether the bearings
are stuck by tilting/rotating the cylinder about its longitudinal axis. It should
be able to rotate freely both in cylinder body end and in the piston end.
30 70001622-1
6. REMEDIAL ACTION
Fault detection and corrective action
Proper installation and commissioning of the cooler, in combination
with regular inspections and control procedures, will ensure trouble-
free operation of hydraulic installations for many years.
In case of operational irregularities, the causative condition(s) must be
identified by means of the hydraulic and electrical diagrams.

6.1 Cylinders
Check whether the cylinders show any sign of leakage. In case of se-
vere leakage (i.e. more than 1 liter per 24-hour period), the cylinder
must be replaced or reconditioned.
Do not forget to check that the length and stroke length of the
new cylinder are identical to those of the cylinder that is to be re-
placed. If not, compensation for any variations must be made at the
suspension arrangement of the cylinder.
In case of piston rod seizure, the piston rod must be reconditioned or
replaced; otherwise, the seals are liable to suffer renewed destruction
within a very short period of time.
If there is any dust in the areas around and on the piston rods, we
would recommend an arrangement which provides mechanical protec-
tion.
Check for presence of abrasive particles etc. which may have a nega-
tive impact on the functionality of the seals. In case the seals are worn
out prematurely, the quality of the oil must be analyzed.

6.1.1 Irregular operation of cylinders

CAUSE 1:
Air content in the oil.
REMEDY:
Vent the pipe system.
CAUSE 2:
The seals of the piston of the cylinder are worn out. This is ascer-
tained when a change of direction is carried out.
REMEDY:
Replace or recondition the cylinders.
 70001622-1 31

CAUSE 3:
Irregular oil flow from pump. Check that the pressures gauges (620)
and (670) indicate pressure in the lines. If no pressure is able to build
up, try again with ball valves (1125) closed to identify the problems on
ether side of them. If it is suddenly able to build up pressure the prob-
lem is at the cylinders (01) or the shuttle valve (1130), and if it is still
not able to build up pressure the problem is at the pump station. Pos-
sibly the proportional valve may not be working with the required level
of regularity, possibly due to the need for adjusting the pump card. If
the pump card is improperly adjusted, this may have a negative effect
on the calibration of the proportional valve, entailing need to recali-
brate the proportional valve. Therefore, it is essential to ensure that
the pump card is adjusted immediately in connection with the observa-
tion of any operational irregularities.
It will be possible to check the zero-point calibration of the proportional
valve by interrupting the electrical connection to the valve, where after
the “rocker cam” of the pump must assume a position at the centre,
resulting in minimum flow rate and oil pressure. Needless to say, this
must not be done in case of normal operating operations.
In case of need to check the pump card of the proportional valves, the
pump concerned must be stopped and the stand-by pump must be
put into operation.
The A and B-strings of the pump must be short-circuited. As a result, it
will be possible to test the pump card and the control system, but, of
course, without any application of pressure in the A and B-line.
REMEDY:
Replace or repair the electrical equipment.
See instruction manual for pump card. In case of improper calibra-
tion of the proportional valve, the valve must be dismantled for exe-
cution of re-calibration procedure.

CAUSE 4:
Error signals from transducer. Check signals from transducer.
REMEDY:
Replace transducer. Do not forget to adjust the transducer. It is essen-
tial to ensure proper alignment of the transducer.

CAUSE 5:
Malfunctioning of the pump. There is nothing wrong with the perform-
ance of the electrical equipment, but there is a mechanical fault in the
pump.
REMEDY:
Repair the pump or affect a switchover to the stand-by pump. If the
pump or booster pump is to be dismantled or prepared for renova-
tion procedure, the pump must be isolated by closing the ball valves
and plugging the drain lines, if this should become necessary. All
32 70001622-1
opened pipes and hoses must be immediately closed with clean
plugs.
CAUSE 6:
Malfunction in shuttle valve.
REMEDY:
Replace or repair valve.

CAUSE 7:
Unstable proportional control valve, or irregular supply of servo
oil to the valve.
REMEDY:
There may be a malfunction of the proportional control valve, neces-
sitating replacement of valve.
Check first for any signs of unstable servo pressure, pressure gauge
(455). See manual from supplier.
Alternatively, the adjustment of control card of the pump is incorrect,
necessitating a re-adjustment of the card. See instruction manual for
electrical equipment.

6.2 Temperature too high

CAUSE 1:
Incorrect adjustment of water valve, evidenced by the fact that no
cooling water or only a very small amount of water is passing through
the water cooler.
REMEDY:
Adjust or clean the valve.

CAUSE 2:
Water supply failure.
REMEDY:
Check the filter (147) in the line in front of valve and clean the filter or
determine the exact point where the water supply is interrupted and
re-establish the connection.

CAUSE 3:
In operation, the hydraulic equipment generates too much heat.
REMEDY:
Determine, by throttling, the exact location where heat is being gener-
ated. An oil pressure exceeding the normal level should be observed
simultaneously with this condition.
Remove any foreign elements or any other obstruction.

CAUSE 4:
Inadequate oil circulation.
REMEDY:
Check the filters (150) and pump (200).
 70001622-1 33

6.2.1 Low oil temperature

CAUSE 1:
Too much cooling water.
REMEDY:
Check the water valve.

CAUSE 2:
Inadequate oil circulation. Only during start-up and in cold environ-
ments.
REMEDY:
Check the heating valve (210) and pump (200).

6.2.2 Alarm for low oil level

CAUSE 1:
Leaks in system, e.g. a loose screwed connection.
REMEDY:
Remedy the leakage and re-fill oil.
Due attention must be given to the risk of oil ignition.
34 70001622-1

6.2.3 No movement of frame

CAUSE 1:
Breakdown of pump. Primary indication: No delivery of oil from pump
during operation.
REMEDY:
Switch operation to the stand-by pump and repair the pump. Check
that coupling between motor and pump is not loose or damaged.

CAUSE 2:
There is no change in the direction of operation of pump.
Reason: Flawed longitudinal transducer or proportional control valve
or its control card or the servo pressure is too low; the latter condition
is ascertainable by checking the reading on pressure gauge (455).
REMEDY:
Replace the longitudinal transducer.
In case of any malfunction of the proportional control valve/control
card, the back-up pump can be put into operation. This also applies if
the servo pressure is low.

CAUSE 3:
The cylinder has moved to the bottom due to malfunctioning in the
control system or the transducer. Evidence of irregularity is provided
by the cylinder or frame or the panel of the electrical control cabinet
and by the fact that the oil pressure of pump is maximized.
For identification of underlying cause, an attempt should be made to
move the frame with the hydraulic system in “local test” mode.
REMEDY:
Repair/replace the electrical equipment.

CAUSE 5:
Blockage of frame. Irregularity is evidenced by the fact that movement
of frame is halted, with oil pressure at maximum level.
REMEDY:
Check that the cooler is not filled completely, which would impede its
movability. Check that the movable frame on the cooler is capable of
unimpeded movement.
If the cooler is filled with hot clinker which are thoroughly “baked” to-
gether, such formations must first be aerated, with the fans of the
cooler being operated at maximum capacity.
Try to move the frame backward and then forward again in the usual
manner. If this cannot be done, this would indicate that the clinker bed
in the cooler is thoroughly baked together. The preset pressure of
about 240 bar can be increased temporarily to a level around 260 bar.
See sub-section 4.1.5. The pressure can subsequently be adjusted
downward to the pressure which is deemed to be necessary.
 70001622-1 35

Alternatively, the sealing profiles/crossbars may be bent to such an

extent that the frames will be blocked. Any such situation must be
remedied by replacing the deformed parts.

6.3 Pumps
Cavitations
Check, on a daily basis, whether the noise level of the pumps during
operation is very high, e.g. due to cavitations. Within a very short time
period, this will cause the pumps to sustain severe damage, and,
therefore, the operation must be immediately switched to the back-up
pump.
The underlying cause must be identified, and, apart from the pos-
sibility of the pipelines being clogged, the problem may be due to
failure of the accumulators or flaws in the booster pump or the
pressure relief valve.
Pump must be restored to full functionality or the pressure must be
adjusted.
The pressure of the accumulators can be checked using
the accumulator precharge kit supplied with the pump sta-
tion and a nitrogen cylinder. Checking the precharge pres-
sure must only be done with the oil pressure released,
which should be ensured by the accumulator safety block
(465) at the instant the pump is stopped. But checking at
gauge (455) is still recommended.
 36 70001622-1

6.3.1 Abnormal noise from pump

CAUSE 1:
Air is sucked in, causing the oil to foam.
REMEDY:
The condition may be due to a malfunction in the servo-/booster
pump. Clean the pipelines or repair/replace the booster pump.
This should be observed as an alarm for pressure controller (490) and
a low pressure on pressure gauge (455).
Check that all connections in the suction line to the pump is properly
tightened, so no air can enter.

CAUSE 2:
Loose connections at pump.
REMEDY:
Tighten any loose assemblies.

CAUSE 3:
The oil level is too low.
REMEDY:
Refill with fresh oil. Check that the level alarms function properly and
determine the source of oil leakage.

6.3.2 Low booster pressure

CAUSE 1:
Faulty pressure relief valve for booster pressure or malfunctioning
servo-/boost pump. The pressure relief valve is positioned inside the
main pump house (315). To investigate, close ball valves (1125) and
start the main pump in manual without angling out. Check the pres-
sure gauge (455). If there is still no pressure one or both of the above
is malfunctioning. This will also have effect on the servo pressure.
REMEDY:
Switch to the stand-by pump and recondition or replace the pump
and/or the pressure relief valve.
CAUSE 2:
Fault in shuttle valve block (1130) which entails that the oil volume fed
to the tank exceeds that supplied by the booster pump.
REMEDY:
Replace the valves. Or replace the shuttle valve block.

6.3.3 High oil pressure

The oil pressure must be recorded and used for controlling the frame
speed when operating with very coarse clinker from the kiln.
Any rise in the oil pressure which is not due to coarse clinker may be
ascribable to obstructions in the system, and hence an increasing
 70001622-1 37

pressure. Usually, this is observed in the form of noise emission and

generation of heat.

CAUSE 1:
Falling of coatings or crust from kiln.
If the high pressures are due to coatings falling from the kiln and con-
gestion in the cooler, there will also be a short-term pressure rise. This
will be evident from the operation of the cooler.
CAUSE 2:
Obstruction in cooler.
High pressures may occur if the cross bars and sealing profiles exert
pressure against the underlying parts, as a result of heat impacting
and deformation.
In case of this situation giving rise to a fall-through of hot material in
the cooler, the operation must be strictly monitored, and, if neces-
sary, corrective action must be taken to prevent any ignition of
spilled oil/oil hoses.

REMEDY:
Adjust the operation of the cooler to eliminate jamming exerted by
hot cross bars and the sealing profiles. The necessary repairs must
be carried out at the earliest possible date.
Excessive build-up of material in inlet
In case the inlet of the cooler is filled with material and the frames are
stopped, the fans of the cooler must be in operation to enable the
drive unit to push away the clinker and to ensure effective cooling
of the grates/cross bars and the clinker bed before any pushing is
done.
The preset pressure of maximum 240 bar can then be used to level
out the piled-up formation, but always remember not to apply the full
grate speed; the maximum allowable speed is 50%. If necessary, the
pressure can be raised temporarily to a level around 260 bar. See
sub-section 6.2.3.

6.4 Noise emission from pipes

CAUSE 1:
Loose pipe clamps.
REMEDY:
Fasten the pipes. Check first whether the surfaces of pipes have
sustained damage. Replace any damaged pipes. Should the problem
recur, the plausible explanation will be: too few pipe clamps or violent
shock impacts in the pipes.

CAUSE 2:
Shock impacts in the pipes, which may be caused by air in the oil, bot-
toming of the cylinders or a malfunction of the shuttle valve. These ir-
38 70001622-1
regularities normally occur during start-up with air in pipes and particu-
larly in the drain line, and will normally disappear within a reasonably
short period of time.
REMEDY:
- Venting
- Check and adjust the movement of the cylinder
- Replace or recondition the shuttle valve

6.5 The maximum frame speed cannot be achieved

CAUSE 1:
Worn pump.
REMEDY:
Operation must be switched to the stand-by pump and the faulty pump
must be reconditioned.

CAUSE 2:
Incorrect adjustment of pump control unit, e.g. excessive duration of
braking and acceleration cycles. Alternatively, the maximum rate of
angling of the pump is restricted on the pump card. See manual for
the piston pump and pump control card.
REMEDY:
Adjust the control unit.

CAUSE 3:
Worn seal in cylinders pistons or internal leak in cylinders.

Remedy:
Change the cylinders and renovate them.
 70001622-1 39

7. APPENDICES

01 Cylinder 435 Limit Switch

100 Tank 440 Hose
115 Air filter 445 Hose
120 Fluid level indicator 450 Boost Oil Filter
125 Level Switches 451 Clogging Indicator
130 Resistance Thermometer 453 Throttle Valve
131 Check Valve 455 Pressure Gauge, Boost Oil
132 Check Valve 460 Accumulator
133 Check Valve 462 Accumulator Warning Label
140 Oil Cooler 465 Accumulator Safety Block
145 Water Valve 467 Bracket Incl. Support Ring
147 Water Filter 470 Clamp
150 Double filter for return oil 490 Pressure Switch, Boost Oil
155 Clogging Indicator 491 Plug-in Connector
160 Check Valve 605 Ball Valve, Stand-by Pump
165 Circulation Oil Filter 610 Limit Switch
185 Quick Coupling 620 Pressure Gauge, A-Line
186 Quick Coupling 625 Throttle Valve
187 Hose 635 Valve Block
187 Hose 655 Ball Valve, Main Pump
190 Ball Valve, 3-Ways 660 Limit Switch
200 Circulation Pump 670 Pressure Gauge, B-line
210 Pressure Relief Valve 675 Throttle Valve
215 Pressure Relief Valve 680 Hose
225 Pressure Gauge, Circulation Oil 682 Connection from Hand Pump
305 Anti Vibration Mount 685 Connection to Hand Pump
307 Hose 690 Hand Pump
308 Hose 695 Pressure Test Connector
310 Check Valve 1001 Hose
311 Ball Valve 1007 Vent Valve
312 Orifice 1020 Hose for cylinder
315 Variable Displacement Pump 1021 Hose for cylinder
320 Electric Motor 1060 Hose
325 Bell Housing 1061 Hose
326 Coupling Motor Hub 1062 Hose
335 Coupling Pump Hub 1125 Ball Valve
340 Flexible Ring Gear 1130 Shuttle Valve
360 Pressure Transmitter 1135 Ball Valve
365 Pressure Test Connector 1140 Flow Switch
366 Hose 1150 Ball Valve for flushing only
367 Hose 1151 Ball Valve for flushing only
370 Hose
430 Ball Valve
 40 70001622-1

Appendix I

100 Tank 310 Check Valve

115 Air filter 311 Ball Valve
120 Fluid level indicator 312 Orifice
125 Level Switches 315 Variable Displacement Pump
130 Resistance Thermometer 320 Electric Motor
131 Check Valve 360 Pressure Transmitter
132 Check Valve 430 Ball Valve
133 Check Valve 450 Boost Oil Filter
140 Oil Cooler 455 Pressure Gauge, Boost Oil
145 Water Valve 460 Accumulator
147 Water Filter 465 Accumulator Safety Block
150 Double filter for return oil 490 Pressure Switch, Boost Oil
605 Ball Valve, Stand-by Pump
155 Clogging Indicator
620 Pressure Gauge, A-Line
160 Check Valve
635 Valve Block
165 Circulation Oil Filter 655 Ball Valve, Main Pump
185 Quick Coupling 670 Pressure Gauge, B-line
186 Quick Coupling 680 Hose
187 Hose 682 Connection from Hand Pump
190 Ball Valve, 3-Ways 685 Connection to Hand Pump
200 Circulation Pump 690 Hand Pump
210 Pressure Relief Valve
215 Pressure Relief Valve
225 Pressure Gauge, Circulation Oil
70001622-1 41

I
42 70001622-1

II

160 Check Valve

310 Check Valve
311 Ball Valve
312 Orifice
315 Variable Displacement Pump
320 Electric Motor
360 Pressure Transmitter
430 Ball Valve
450 Boost Oil Filter
455 Pressure Gauge, Boost Oil
460 Accumulator
465 Accumulator Safety Block
490 Pressure Switch, Boost Oil
605 Ball Valve, Stand-by Pump
620 Pressure Gauge, A-Line
635 Valve Block
655 Ball Valve, Main Pump
670 Pressure Gauge, B-line
685 Connection to Hand Pump
1001 Hose
70001622-1 43

II
44 70001622-1

III

01 Cylinder
1001 Hose
1007 Vent Valve
1020 Hose for cylinder
1021 Hose for cylinder
1060 Hose
1061 Hose
1062 Hose
1125 Ball Valve
1130 Shuttle Valve
1135 Ball Valve
1140 Flow Switch
1150 Ball Valve for flushing only
1151 Ball Valve for flushing only
70001622-1 45

III
46 70001622-1

IV

100 Tank
115 Air filter
120 Fluid level indicator
125 Level Switches
130 Resistance Thermometer
140 Oil Cooler
145 Water Valve
147 Water Filter
150 Double filter for return oil
155 Clogging Indicator
185 Quick Coupling
186 Quick Coupling
187 Hose
190 Ball Valve, 3-Ways
200 Circulation Pump
210 Pressure Relief Valve
215 Pressure Relief Valve
225 Pressure Gauge, Circulation Oil
680 Hose
682 Connection from Hand Pump
690 Hand Pump
70001622-1 47

IV
48 70001622-1

V
360 Pressure Transmitter
605 Ball Valve, Stand-by Pump
610 Limit Switch
620 Pressure Gauge, A-Line
625 Throttle Valve
635 Valve Block
655 Ball Valve, Main Pump
660 Limit Switch
670 Pressure Gauge, B-line
675 Throttle Valve
685 Connection to Hand Pump
695 Pressure Test Connector
70001622-1 49

V
50 70001622-1

VI

160 Check Valve 430 Ball Valve

305 Anti Vibration Mount 435 Limit Switch
307 Hose 440 Hose
308 Hose 445 Hose
310 Check Valve 450 Boost Oil Filter
311 Ball Valve 451 Clogging Indicator
453 Throttle Valve
312 Orifice
455 Pressure Gauge, Boost Oil
315 Variable Displacement Pump
460 Accumulator
320 Electric Motor 462 Accumulator Warning Label
325 Bell Housing 465 Accumulator Safety Block
326 Coupling Motor Hub 467 Bracket Incl. Support Ring
335 Coupling Pump Hub 470 Clamp
340 Flexible Ring Gear 490 Pressure Switch, Boost Oil
360 Pressure Transmitter 491 Plug-in Connector
365 Pressure Test Connector
366 Hose
367 Hose
370 Hose
70001622-1 51

VI

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