INSTRUCTION MANUAL .

Motors for rotary kilns 70000723-1

Kilns with friction drive

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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List of contents: Page:

1. Mode of operation ....................................................................................... 4

2. Output ......................................................................................................... 4
3. Main motors, type and design ...................................................................... 5
4. Speed control .............................................................................................. 6
5. Starting conditions ...................................................................................... 7
6. Damping of torsional vibrations, dual drives............................................... 9
7. Reverse rotation when the kiln is stopped .................................................. 10
8. Turning of kiln .......................................................................................... 11
9. Inclination of motor shaft .......................................................................... 11
10. Direction of rotation ................................................................................ 11

Edited by: KelH Translated by: Pages:

Approved by: MGN code: T600 17
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Appendices:
Page:
Appendix 1. Power and torque requirements ............................................................................... 13
Appendix 2. Definition of heavy and easy start ............................................................................ 15
Appendix 3. PWM Vector Control Diagram .................................................................................. 17
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1. Mode of operation

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, maintenance of
the plant, machine, equipment 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.

The motors/drives must be sized and engineered for

continuous operation corresponding to duty type S1 according
to IEC 34-1, i.e. 24-hour operation for prolonged periods.
(Approx. 8000 h/year).

2. Output

The motor and drive output at nominal speed, nnom , and

maximum speed n max and the speed range are specified in the
order.
From minimum speed, n min, to nominal speed, n nom , the motor
must yield a constant torque. From nominal speed, n nom , to
maximum speed, nmax, the motor must work with constant
power, see Appendix 1.
With dual drive the difference in power consumption between
the two motors must be less than 5%.
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3. Main motors, type and design

Main motors are AC squirrel-cage motors controlled by

frequence converters for speed regulation.
The motors drive their individual kiln supporting roller through
cardan shaft coulings.

Motor bearings and shaft must be designed to take up axial

forces, radial forces and weight loads from the cardan shaft
coupling.
The following formulas give approximate values which can be
used for calculation of motor bearings. Relevant formulas for
calculating radial and axial load demends on the required
motor start torque, see order (200 or 250%).

Use motor torqueT at nominal speed n nom .

Radial force, normal operation, 100% load:

F R1 [N] = ± T [Nm] * 0,013

Radial force, starting torque, 200% load:

F R2 [N] = ± T [Nm] * 0,026
or
Radial force, starting torque, 250% load:
FR2 [N] = ± T [Nm] * 0,033

Axial force, normal operation, 100% load

F A1 [N] = ± T [Nm] * 2,5

Axial force, starting torque, 200% load

FA2 [N] = ± T [Nm] * 5,0
or
Axial force, starting torque, 250% load
FA2 [N] = ± T [Nm] * 6,25
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Vertical weight load

FG [N] = T [Nm] * 0,08

4. Speed control

Irrespective of load torque variations, the speed control must

be stable over the entire speed range.

A kiln speed expressed in rpm or sec. per revolution is the

mean value of the kiln speed during one revolution of the kiln.
Independent of the selected type of motor drive system, the
kiln speed must be adjusted and maintained with the accuracy
described in sub-section 4.1.

4.1
The following requirements apply to AC drive systems with
frequency converters (VFD) only:

4.1.1
The kiln speed must be maintained within a relative accuracy
of ±1% within one complete kiln revolution.

This requirement must be met over the entire speed range

without any adjustment of the reference equipment
(potentiometer, current signal or similar) irrespective of load
torque and temperature variations and with a variation of
±10% of the rated supply voltage.

4.1.2
The speed reference equipment must be designed so that the
actual kiln speed can be controlled and instrument readings
can be taken with an accuracy of 1% of the kiln reference
speed within the speed range from Nnom to Nmax.
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In the speed range from 0.1∙n max to n nom the speed must be
controlled with an accuracy of 5% at 0.1∙n max dropping to 1%
of the kiln reference speed at n nom .

5. Starting conditions

5.1
Motor and converter equipment must be able to yield the
maximum initial torque as specified in the order (normally
200-250 % of full-load torque) from 0 to 0.1∙n max during the
entire starting period, see Appendix 1.
The maximum initial torque must be yielded even under
adverse working conditions, under which the starting period
may become the time (including acceleration time) it takes to
turn the kiln through 120O at the lowest working speed
0.1∙n nom .
See example of “heavy start” at a load torque of 200-250% of
full-load torque, Appendix 2.

5.2
Concerning the requirement to the time for turning the kiln at
the mentioned low speeds, the accuracy will be sufficient if
the requirement specifies that the drive must be capable of
yielding the starting torque (“heavy start”) for 60 seconds at
least once per hour reckoned from cold condition.

5.3
In order not to overstrain the mechanical transmission
between motor and kiln, the motor torque must at no time
exceed the initial torque as specified in the order, normally
200 or 250 % of full-load torque.

5.4
The working speed range for the motor must be 0.1∙n max to
n max.
The drive system must be thermally designed according to
this speed range and to the requirements specified in sub-
sections 5.1 and 5.2.
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5.5
Start of the kiln is normally taking place with the charge of
material (inside the kiln) positioned at the angle of repose,
(i.e. side-heavy position).
This means that the start is normally considered as a “heavy
start”, see Appendix 2.
In order to be considered an “easy start”, the charge of
material inside the kiln must be in neutral position, see
Appendix 2.

5.6
The motors must be able to perform a flying start while the
auxiliary drive is in operation.
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6. Damping of torsional vibrations, dual drives

The two motors are connected to the gears through elastic

couplings (cardan shaft couplings) The drive can thus be
considered forming a three-mass oscillation system. Such
systems have two natural oscillation modes with
corresponding frequencies, see Figs. 1 and 2. The oscillations
can be excited by any small mechanical irregularity and grow
excessively if not damped.

Mode 1:
The motors are oscillating in opposite phase.
One runs up in speed, while the other slows
down and vice versa. The motors thus
alternate to pull the kiln, which maintains a
constant speed. In this mode the mechanical
damping is practically zero and electrical
damping is thus a must. The frequency is low,
usually between 8-15 Hz. See Fig. 1.
Fig. 1.
Mode 1 oscillations.

Mode 2:
The motors are oscillating in phase and opposite
to the kiln. That is, when the motors speed up,
the kiln slows down and vice versa. This mode
seldom causes problems due to a certain
mechanical damping and the normal kiln speed
control. The frequency is higher than in mode 1,
usually between 10-15 Hz. See Fig. 2.
Fig. 2.
Mode 2 oscillations.
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The motor/control system must be designed to dampen these

oscillations. That can be provided by a sloping torque relative
to the speed characteristics of each motor corresponding to
constant voltage/frequency.
A normal way, however, has been to design the control
system with a fast inner loop maintaining a constant torque) of
each motor and then adjust the current reference values by
tacho signals, thus actively dampening oscillations. It must be
stressed that it is necessary to control each current reference
individually to provide damping of Mode 1.
A simple way is to let each motor have its own speed control
and use a common speed reference. Should there be a slight
difference in torque between the two drives a correction is
added to the slave reference as shown on Appendix 3. This
system will dampen both modes, provided that the torque
equalizing loop is much slower than the mode 1 frequency.

7. Reverse rotation when the kiln is stopped

The auxiliary drive is equipped with a centrifugal brake which

prevents that the kiln motor is driven in the opposite direction
of rotation by the charge in the kiln immediately after the
power supply is switched off.
This centrifugal brake in the auxiliary drive means that if the
kiln is reversed to neutral position, i.e. with the charge at the
bottom, this is done with a controlled slow reversal speed, not
exceeding the main motor speed.

However, the motor must therefore be tested at an overspeed

of 1.2∙n max. This ensures that the motor is safe regarding
mechanical design.
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8. Turning of kiln

The rotary kiln can be turned for a prolonged period at

reduced speed (approximately 2 - 5% of nmax) by means of a
separate motor and auxiliary gear unit.
Since the kiln motor is mechanically connected during turning,
but electrically unloaded, the motor bearings must be
designed taking this mode of operation in consideration.

9. Inclination of motor shaft

The motor, in particular the bearings, must be designed so

that the motor can be mounted with an inclination of the motor
shaft, normally between 2 and 3 degrees.
The inclination related to horizontal level and whether the
shaft extension is placed highest or lowest is specified in the
order.

10. Direction of rotation

The direction of rotation of the motor is specified in the order.

(The motor may be driven in the reverse direction - refer
section 7.)

--oOo--
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Appendix 1. Power and torque requirements

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Appendix 2. Definition of heavy and easy start

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Nomenclature for PWM Vector Control Diagram

Parameter Explanation
nref,M1 Common reference speed master/follower
motor [rpm.]
nM1 Motor speed master [rpm.]
nM2 Motor speed follower [rpm.]
Tref,M1 Torque reference master [Nm]
Tref,M2 Torque reference follower [Nm]
Tact,M1 Actual torque master [Nm]
Tact,M2 Actual torque follower [Nm]
UM1 Stator voltage master [V]
UM2 Stator voltage follower [V]
fs1 Stator frequency master [Hz]
fs2 Stator frequency follower [Hz]
Is,M1 Stator current master [A]
Is,M2 Stator current follower [A]
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Appendix 3. PWM Vector Control Diagram