INSTRUCTION MANUAL

Motors for rotary kilns

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Kilns with gear rim transmission

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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List of contents:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Page:

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

Output........................................................................................................ 4
Speed control............................................................................................ 5
Starting conditions.................................................................................... 6
Damping of torsional vibrations, dual drives .......................................... 8
Reverse rotation when the kiln is stopped ............................................. 9
Barring of kiln.......................................................................................... 10
Inclination of motor shaft ....................................................................... 10
Direction of rotation................................................................................ 10

Edited by:
Approved by:

KelH
N-PB

Translated by:
MGN code:

Pages:

T600

15

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Appendices:
Page:
Appendix 1. Power and torque requirements.............................................. 11
Appendix 2. Definition of heavy and easy start........................................... 13
Appendix 3. PWM Vector Control Diagram................................................. 15

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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 motor(s)/drive(s) 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, n nom , and
maximum speed nmax 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, n max, the motor must work with constant
power, see Appendix 1.
In case of dual drive the difference in power consumption
between the two motors must be less than 5%.

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3. 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 3.1.

3.1
The following requirements apply to AC drive systems with
frequency converters (VFD) only:

3.1.1
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.

3.1.2
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.
In the speed range from 0.1nmax to n nom the speed must be
controlled with an accuracy of 5% at 0.1n max dropping to 1%
of the kiln reference speed at nnom .

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4. Starting conditions
4.1
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 0.1n 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
O
turn the kiln through 120 at the lowest working speed
0.1n nom .
See example of heavy start at a load torque of 200-250% of
full-load torque, Appendix 2.

4.2
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.

4.3
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.

4.4
The working speed range for the motor must be 0.1n max to
n max.
The drive system must be thermally designed according to
this speed range and to the requirements specified in subsections 4.1 and 4.2.

4.5
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).

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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.

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5. Damping of torsional vibrations, dual drives

The two motors (with gears) are connected to the kiln through
elastic couplings (torsion shafts). 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 1-3 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 2-5 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 current (=
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.

6. Reverse rotation when the kiln is stopped

The barring device is equipped with a releasable backstop
with 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 releasable backstop with centrifugal brake in the barring
device 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 1.2nmax. This ensures that the motor is safe regarding
mechanical design.

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7. Barring of kiln
The rotary kiln can be barred for a prolonged period at
reduced speed (approximately 2 - 5% of n max) by means of a
separate motor and barring gear unit.
Since the kiln motor is mechanically connected during barring,
but electrically unloaded, the motor bearings must be
designed taking this mode of operation in consideration.

8. 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.

9. 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 6.)

--oOo--

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Appendix 1. Power and torque requirements

11

12

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Appendix 2. Definition of heavy and easy start

13

14

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Nomenclature for PWM Vector Control Diagram

Parameter

nM1
nM2
Tref,M1
Tref,M2
Tact,M1
Tact,M2

Explanation
Common reference speed master/follower
motor [rpm.]
Motor speed master [rpm.]
Motor speed follower [rpm.]
Torque reference master [Nm]
Torque reference follower [Nm]
Actual torque master [Nm]
Actual torque follower [Nm]

UM1
UM2
fs1
fs2
Is,M1
Is,M2

Stator voltage master [V]

Stator voltage follower [V]
Stator frequency master [Hz]
Stator frequency follower [Hz]
Stator current master [A]
Stator current follower [A]

nref,M1

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Appendix 3. PWM Vector Control Diagram

15