POLYTRACK® Clinker Cooler With Intermediate Crusher

Machine manual
en-PQ.CPT.001.B
POLYTRACK® clinker cooler with intermediate crusher
Code word
Order number
POLYSIUS Order Code (POC)

Machine manual Contents
®
POLYTRACK clinker cooler with intermediate crusher
Contents
1 Safety 1-1
2 Technical data 2-1
3 Components and mode of functioning 3-1
3.1 Components 3-1
3.2 Mode of functioning3-22
4 Transport and assembly 4-1
4.1 Transportation and storage instructions 4-1
4.2 Assembly 4-2
4.3 Module types 4-3
4.4 Sequence of assembly 4-4
5 Lubrication 5-1
6 Commissioning 6-1
6.1 Checks prior to the test run 6-1
6.2 Test run 6-2
6.3 Drying the refractory lining 6-3
6.4 Setting and adjustment 6-3
7 Operation 7-1
7.1 Operation 7-1
7.2 Starting up 7-2
7.3 Shutting down 7-3
8 Maintenance 8-1
8.1 Safety instructions 8-1
8.2 Inspection 8-3
8.2.1 Inspection during operation 8-3
8.2.2 Inspection during stoppage of the kiln plant 8-4
8.3 Servicing 8-5
8.4 Repair 8-7
8.4.1 The following repair work is described or mentioned:8-8
8.4.2 Replacing aeration units of the static grate 8-9
8.4.3 Replacing the nozzles of the air blast unit 8-12
8.4.4 Repairing the HORSE SHOE brickwork 8-13
8.4.5 Replacing the transport tracks 8-14
8.4.6 Replacing aeration units 8-16
8.4.7 Replacing transport track mounting plates 8-17
8.4.8 Replacing sealing frames 8-18
8.4.9 Replacing the spring system 8-19
8.4.10Replacing the slide rails 8-21
8.4.11 Replacing the slide plate holders 8-23
8.4.12Replacing slide plates 8-25
8.4.13Replacing the bearing blocks 8-28
8.4.14Replacing the fishplates and pins of the longitudinal girder 8-30
en-PQ.CPT.001.B
Contents Machine manual
®
POLYTRACK clinker cooler with intermediate crusher
8.4.15Replacing the thermocouples for temperature measurement on the

transport tracks 8-31
8.4.16Replacing the air distributors and orifice plates 8-33
9 Trouble shooting 9-1
9.1 Faults, causes and elimination of faults 9-3
10 Spare parts10-1
10.1 Suggestions for enquiries and orders of spare parts 10-1
10.2 Spare parts10-1
11 Appendix 11-1
11.1 Technical drawings 11-1
11.2 Subsuppliers' documentation 11-1
en-PQ.CPT.001.B
Machine manual Safety
®
POLYTRACK clinker cooler with intermediate crusher 1
1 Safety
Note
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use
● The machine is exclusively intended for burning small-sized or granulated

feed material. Be sure to comply with the specifications of the intended use in
the section Technical data.
● Any use other than the intended use is forbidden. POLYSIUS AG is not
responsible for damage resulting from any use other than the intended use. All
other use is at the owner's own risk.
● The intended use also includes observance of the instructions in the machine
manual and compliance with the maintenance instructions.
Transport and assembly
● All transportation instructions in this machine manual refer exclusively to the
transport of the machine at the plant site.
● Only use suitable hoisting and load-carrying equipment which is in serviceable
order and has a sufficient load-bearing capacity.
● Never work under a suspended load.
Operation
● Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and
recording of such checks.
● If changes in the machine or its operating behaviour occur that are relevant to
safety, shut it down immediately.
● Hearing protectors must be worn in the area of the cooler as the noise level
exceeds 90 dB(A).
en-PQ.CPT.001.B
Safety Machine manual
®
2 POLYTRACK clinker cooler with intermediate crusher
Maintenance
● Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the maintenance work.
● Make absolutely sure that all parts of the machine have come to a complete
standstill before you remove any protection devices or open any covers.
● Before performing any work on the machine, make sure there is no risk of
burns when touching it.
● Be sure to wear proper protective clothing for work on the hot clinker cooler.
● Hearing protectors have to be worn in the vicinity of the clinker cooler because
the noise level can exceed 90 dB (A).
● When using automatic air blast units, let the residual pressure escape after
the air blast unit has been electrically switched off before opening the doors
and poke holes. Danger of unintentional shooting due to residual pressure.
● Directly after the machine has been shut down, you must only enter the
interior wearing a breathing apparatus with independent ventilation. You are
not allowed to enter the interior without a breathing apparatus until you have
sufficiently purged it with fresh air. Make sure that there is sufficient oxygen
inside the machine and that no hot gases can enter.
● Doors and sealing covers may only be opened by specially authorised and
trained personnel on the express orders of the plant manager! Make sure that
all doors and sealing covers are secured with padlocks.
● Before performing any work on the machine, make absolutely sure that there
is no hot material in it when inspection covers and service covers are opened.
● When work is being performed inside the machine, make absolutely sure that
fresh air is supplied continuously (by injection or suction), so that the inhaled
air remains free of noxious constituents. Aeration with pure oxygen is
forbidden.
● Make absolutely sure that nobody can gain access to the clinker cooler while
the preheater or the rotary kiln is being cleaned. It is possible that raw meal
could flush through the kiln and into the clinker cooler. There is danger of
being buried alive and dying of suffocation.
● For maintenance work to be carried out inside the plant, you may have to
install auxiliary platforms. These auxiliary platforms must be of stable
construction.
● Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily inflammable substances for cleaning the
machine.
● Make absolutely sure that all piping is depressurised.
● Switch off the power supply to the electrical components before beginning any
maintenance work.
● The hydraulic system has been specially designed for the supplied machine
and must therefore not be used for any other machine without the express
consent of POLYSIUS AG.
en-PQ.CPT.001.B
Machine manual Safety
®
● Make absolutely sure that the hydraulic piping is depressurised before it is

disconnected.
● Never use the main pumps of the hydraulic system to empty or fill the oil tank.
● If you drain hydraulic oil at operating temperature, you risk scalding yourself.
● After all maintenance work, check that there are no leaks in joints and
connections.
Flame cutting, grinding or welding work
● You have to obtain the written permission of the plant manager before you
start any flame-cutting, grinding or welding work, and you must shut down the
plant section in which the roller mill is installed.
● Strictly observe the welding instructions when performing any welding work.
● When electric arc welding or cutting is being performed, you must ensure that
personnel cannot come into contact with electrically conductive components.
Use insulating underlays for this purpose.
● Never situate the source of the welding current in a confined space where
walls have conductive properties. Only use 24 volt lamps to illuminate the
interior of the machine.
● If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, hydraulic cylinders, other
moving connecting elements or measuring devices. Always directly connect
the welding current return lead to the part being welded.
Conclusion of maintenance work
● After having finished all maintenance work, check all joints and connections
for leaks.
● Remount all protection devices when the maintenance work has been
finished. Make absolutely sure that no persons are inside the plant component
before you properly close the inspection and service covers.
● Check that all signs are complete and distinctly legible. Mount new signs if
necessary.
en-PQ.CPT.001.B
Machine manual Technical data
®
2 Technical data
Note
Information concerning the electrical equipment is contained in the separate
electrical documentation or in the subsuppliers' documentation.
Specification of the intended use

Material to be cooled Cement clinker
Basic data
Construction size
Number of transport tracks
Number of modules over cooler length
Number of modules over cooler width
Width of the aeration floor mm
Length of the aeration floor mm
Area of the aeration floor m2
Area of the aeration floor (actively m2

aerated)
Number of aeration floors
Inclination of the cooler and of the °

aeration floors
Offset between longitudinal cooler mm

axis and longitudinal kiln axis
Offset of longitudinal cooler axis left/right

viewed against the flow direction of
cooling material
Temperature monitoring system for the transport tracks

Alarm for the transport tracks °C
Air blast unit

Type
Qty.
en-PQ.CPT.001.B
Technical data Machine manual
®
Drive
See machine manual No.
Roll crusher
See machine manual No.
Aeration of the POLYTRACK® clinker cooler
Fan no. Compartment no. Volume flow Static pressure

3
[m /h] [mbar]
Aeration of upper
housing section
en-PQ.CPT.001.B
Machine manual Components and mode of functioning
®
3 Components and mode of functioning
3.1 Components
Note
Some details of the drawings in this manual may not be identical with the
drawings supplied under the contract.
en-PQ.CPT.001.B
Components and mode of functioning Machine manual
®
Fig. 1: POLYTRACK® assembly
en-PQ.CPT.001.B
®
No. Name Description
1.0 Grate equipment
2.0 Longitudinal girder with bearing assembly
3.0 Grate substructure
3.1 Cross girder
4.0 Lower housing section
4.10 Viewport divided
4.20 Partition upper
4.30 Partition lower
4.11 Sealing flap
5.0 Upper housing section
5.1 Exhaust air duct socket
6.0 Air blast unit
9.0 Doors and inspection ports
10.1 Thermocouples
14.0 Drive
20.0 Roll crusher
21.0 Fans are not shown in the figure
22.0 Refractory lining
en-PQ.CPT.001.B
®
Static pre-grate (1.20)
Fig. 2: Static pre-grate
en-PQ.CPT.001.B
®
1.20 Static pre-grate initial zone of the static grate
1.21 Aeration unit
1.22 Aeration unit in front of

nozzle
1.23 Cover plate
1.24 Nozzle for air blast unit
1.27 Protective plate
1.28 Connecting sleeve for nozzle
1.29 Connections for air distributors
1.30 HORSE SHOE
en-PQ.CPT.001.B
®
Grate equipment (1.0)
Fig. 3: Grate equipment
en-PQ.CPT.001.B
®
1.0 Grate equipment including static pre-grate
1.1 Conveying element Transport track
1.2 Aeration unit Aeration floor
1.3 Mounting plate for transport track
1.4 Pin for transport track
1.5 Angle bracket
1.6 Sealing frame
1.7 Spring system
1.8 End cover
1.9 Intermediate piece
1.10 Dam plate
en-PQ.CPT.001.B
®
Items shown in the drawing of the spring system (1.7)
Fig. 4: Spring system
en-PQ.CPT.001.B
®
No. Name
1.7 Spring system
1.7.1 Spring system, vertical
1.7.2 Spring system, horizontal
en-PQ.CPT.001.B
®
Items shown in the air distribution diagram (1.50)
Fig. 5: Air distribution diagram
en-PQ.CPT.001.B
®
1.50 Air distribution diagram
1.51 Air distributor Air distributor
1.52 Air distributor, narrow Air distributor
1.55 Orifice plate
1.56 Orifice plate narrow
en-PQ.CPT.001.B
®
Longitudinal girder (2.0) with bearing assembly
Fig. 6: Longitudinal girder with bearing assembly
en-PQ.CPT.001.B
®
2.0 Longitudinal girder with bearing assembly
2.1 Longitudinal girder
2.2 Slide rail
2.3 Bearing block divided
2.3.1 Basic body
2.3.2 Slide plate holder
2.3.3 Bolted connection Slide plate holder
2.4 Slide plate
2.5 Fishplate Longitudinal girder
2.6 Pin Longitudinal girder
en-PQ.CPT.001.B
®
Items shown in the drawing of the doors and inspection ports (9.0)
Fig. 7: Doors and inspection ports
en-PQ.CPT.001.B
®
No. Name
9.1 Seal for access door (1650 x 1500)
9.10 Inspection port, complete
9.10.1 Glass pane for inspection port
9.10.2 Seal for glass pane of inspection port
en-PQ.CPT.001.B
®
Items shown in the drawing of the lighting (9.20)
Fig. 8: Lighting
en-PQ.CPT.001.B
®
9.20.1 Protection pipe
9.20.2 Flap
9.20.3 Supporting tube
9.20.4 Lamp
9.20.5 Glass for the lamp
9.20.6 Protective basket for the lamp
en-PQ.CPT.001.B
®
Thermocouple (10.1)
Fig. 9: Thermocouple
en-PQ.CPT.001.B
®
10.1 Thermocouple
10.2 Fastening
10.3 Connecting cable
10.4 Protective pipe for the connecting piping
10.10 Measuring point in the transport track
en-PQ.CPT.001.B
®
Travel measuring system (14.10)
Fig. 10: Travel measuring system
en-PQ.CPT.001.B
®
14.0 Drive
14.10 Travel measuring system
14.11 Holder for the measuring system
14.12 Holder for the magnet
14.13 Magnet
14.14 Connecting cable for the measuring system
14.15 Protective pipe for the connecting cable
en-PQ.CPT.001.B
®
3.2 Mode of functioning

The POLYTRACK® clinker cooler is designed for the cooling of small-sized or
granulated pyroprocessed material.
To cool the material, cold air is blown from below through the aeration floor and
through the bed of cooling material lying on the aeration floor.
The pyroprocessed material discharged from the rotary kiln falls through the inlet
shaft of the clinker cooler and onto the static pre-grate.
The POLYTRACK® clinker cooler is a combination of a static aeration floor with
an above-floor conveying device operating like a shuttle floor. The conveying
elements are transport tracks which are arranged parallel to each other in the
conveying direction with a certain distance between them. The entire cooler is of
modular design. 3 module widths are supplied, namely 1.5 m, 2.0 m and 2.5 m.
These modules are combined to make up the required width of the cooler. The
module length is 4.8 m. Adjustment lengths of 2.4 m are possible.
The upper housing section has a refractory lining and a fireproof ceiling.
In the front end of the clinker cooler, the heated air is drawn from the upper
housing to be used in the kiln plant as secondary air or tertiary air (if a tertiary air
duct is installed). The exhaust air from the last section of the cooler is either
discharged into the atmosphere via a deduster or supplied to other plant sections,
e.g. for drying raw material.
The clinker cooler has openings for measurements and a TV camera (optional),
as well as doors and inspection ports for monitoring the interior during operation
and for inspection and maintenance work during stoppages.
The clinker cooler with intermediate crusher has at least two separate,
hydraulically driven aeration floors. The aeration floors can be horizontal or
inclined. At the end of the first aeration floor, a special clinker sampling device
can be installed below the roll crusher.
To transport the cooling material the entire transport track system moves forward
in the direction of transportation by a stroke length of approx. 100 to 230 mm,
pushing the material along with it. The transport tracks then perform the return
stroke separately. A POLYTRACK® with 5 transport tracks thus performs the
following movements:
First, transport tracks 1 and 4 are moved backwards by the stroke length, then
transport tracks 2 and 5, and finally transport track 3. This concludes one cycle of
movements. In the next phase, this cycle is repeated. The material on the cooler
floor is transported by the forward strokes. During the individual return strokes,
the frictional force between the transport tracks and the material is not great
enough to convey the material backwards.
en-PQ.CPT.001.B
®
Fig. 11: Example of a POLYTRACK® with 5 transport tracks
M Material flow direction
V Forward stroke
1. 1st return stroke
2. 2nd return stroke
3. 3rd return stroke
The transport tracks are driven hydraulically. Cylinders attached to the transport
tracks move them in the respective direction. The forward and return movements
of the cylinders are controlled by a swivelling axial piston pump. A separate axial
piston pump is assigned to each transport track, so that the tracks can be
controlled independently of each other.
The conveying speed of the material can be set within a wide range. It depends
on the cycle time of the forward and backward movements of the transport tracks
and on the adjustable stroke length.
Since the stroke length is separately adjustable for each transport track, any
desired transport profile can be set for the material. You can, for instance, set the
outer transport tracks to 150 mm stroke length and the transport track in the
centre to 200 mm.
This way, the clinker distribution and the bed depth can be adjusted over the
width of the cooler to suit the discharge conditions of the kiln.
en-PQ.CPT.001.B
®
The moving longitudinal girders, on which the transport tracks are fastened, are
seated in sliding bearings inside the cooling air compartment underneath the
aeration floor.
Two bearing blocks are installed at each bearing point to guide the longitudinal
girders in the vertical and horizontal directions. A plastic fabric laminate with
embedded dry lubricant particles is used as bearing material. No additional
lubrication is required.
The moving mounting plates between the transport tracks and the static aeration
floor are sealed by means of horizontal sliding seals. The sliding surfaces are of
machined hard facing. The lower static part of the pair of seals is pressed by
springs against the upper part, which moves in the longitudinal direction of the
cooler. This ensures safe sealing even in the case of deformations and
settlements.
Special aeration units distribute the cooling air into the clinker bed. Labyrinths
prevent the clinker from entering the cooling air compartment. The air outlet zone
and the floor of the aeration unit are protected against wear by a static clinker
bed.
The lower housing section (4.0) is subdivided into air chambers by partitions
(4.20 and 4.30).
The lower housing section (4.0) consists of the modular grate substructure, the
end walls and the sidewalls. In a POLYTRACK® clinker cooler, only a minimal
amount of material falls through the grate, or none at all.
The grate substructure (3.0) absorbs the vertical loads from the bed of clinker and
the dead weights that mainly arise from the transport tracks, aeration units and
longitudinal girders with bearings. The grate substructure also absorbs all the
horizontal drive loads.
Depending on the width of the clinker cooler, the substructure can consist of one
module width (up to max. 2.5 m) or can be made up of several module widths
(1.5, 2.0, 2.5 m).
The grate length is made up of length modules of 4.8 and 7.2 m length.
To convey the clinker, all transport tracks are pushed forward in the clinker cooler
in longitudinal direction. Each transport track is driven by at least 2 hydraulic
cylinders.
The hydraulic cylinders are actuated in a closed hydraulic circuit.
en-PQ.CPT.001.B
®
The grate equipment consists of the static pre-grate (1.20), the static grate with
aeration units (1.21, 1.22) and the subsequent aeration floors with transport
tracks (1.1) arranged in lengthwise direction, which essentially move above the
aeration units (1.2) to convey the clinker.
In the POLYTRACK®, the functions of clinker transport and clinker cooling are
separated.
To prevent damage of the grate equipment due to overheating, some transport
tracks (1.1) are fitted with thermocouples (10.1) for temperature monitoring.
These thermocouples enable the operator to react in good time to temperature
differences.
Cooling air supply system / aeration system
The cooling air is delivered by fans (21.0) and routed via aeration piping to the
aeration compartments underneath the aeration floor.
The lower housing section (4.0) is divided into compartments, with each
compartment being assigned to one of the fans (21.0). At locations where the
cooling air passage has to be reduced for process technological reasons, air
distributors or orifice plates can be inserted. This enables specifically directed
aeration of the aeration floor and the material to be cooled.
By means of throttle devices with actuators and/or by means of variable-speed
drives, the cooling air flow rate delivered by each fan can be suited to the process
technological and mechanical requirements.
en-PQ.CPT.001.B
Machine manual Transport and assembly
®
4 Transport and assembly
4.1 Transportation and storage instructions

The drive is transported in individual parts or in subassemblies. Make absolutely
sure that suitable lifting equipment is employed for lifting all the parts from the
transport vehicles and transferring them to the storage area.
When they arrive at the site, all parts must be inspected for transport damage and
placed on wooden beams with the provision of suitable protection against
moisture, soiling and damage. Never place the parts directly on the ground.
Make absolutely sure that motors, couplings, gear units and measurement and
control equipment are stored in well-ventilated rooms and protected against
moisture.
Gear unit
Make absolutely certain that carrying ropes are only fastened at the envisaged
points.
Take special care with the transportation of gear units already equipped with oil
pumps and piping. Prior to any transportation, remove the piping and close all
pipe sockets and openings with weather and impact-proof sealing covers to
prevent ingress of tramp material. Make sure that all sealing covers can be easily
removed.
Transportation and storage instructions for the following subassemblies
● the drive (14.0)

● the roll crusher (20.0)
● the fans (21.0)
● the refractory lining (22.0)
are contained in the separate machine manuals and the documentation of the
relevant subsupplier.
en-PQ.CPT.001.B
Transport and assembly Machine manual
®
4.2 Assembly
Required personnel
To ensure correct performance of the work, it is important that all the assigned
personnel have received special training for the tasks to be performed.
Note
It is a prerequisite of our warranty that assembly supervision and assembly
inspection are performed by a specialist from POLYSIUS AG.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need torque wrenches of a
bigger size than normal and suitable hydraulic pumps.
Whether or not you need auxiliary equipment, such as scaffolds or auxiliary
supports, depends on the operating conditions in your plant.
NOTE
The basic safety instructions must be complied with. Also refer to the section
Safety
CAUTION
Welding current
Moving connecting elements or sliding surfaces can be damaged.
I. Always directly connect the welding current return lead to the part
being welded.
II. Never conduct the welding current through plain or antifriction
bearings, hydraulic cylinders, other moving connecting elements or
measuring devices.
Note
The following assembly description does not detail the individual steps for
assembling the machine, but rather gives an overview of the work to be
performed.
Changes in the planning of the plant during the processing of the contract may
lead to deviations from this assembly description.
en-PQ.CPT.001.B
®
4.3 Module types
Fig. 12
A = static pre-grate
B = initial module
C = middle module
D = end module
The figure shows the modular design of the POLYTRACK ®. The individual
modules arrive at the plant site in preassembled condition and are then fitted
together to form the complete length and width of the cooler. Additional parts
have to be mounted at the points of connection of the modules. Details are
provided in the drawings specially prepared for the site assembly.
en-PQ.CPT.001.B
®
Fig. 13: Example of cooler assembly (without upper section of the cooler)
4.4 Sequence of assembly
Sequence of assembly
Note
The assembly sequence can be subject to modification due to local conditions.
After completion of important assembly steps, document them by means of
measurement records.
● Measure and mark the longitudinal and transverse axes. Check the foundation
levels and inscribe the reference height marks on the building.
en-PQ.CPT.001.B
®
Fig. 14: Checking record
A = longitudinal kiln axis G = transverse axis marks
B = cooler offset H = direction of conveyance

(depending on the direction of kiln
rotation)
C = longitudinal axis of cooler I = left-hand side of cooler
D = transverse axis of cooler K = right-hand side of cooler
E = marks on building L = cooler housing / grate substructure
F = longitudinal axis marks
en-PQ.CPT.001.B
®
● Align and anchor the base frame (optional).
Note
The POLYTRACK® housing has no floor. The substructure has to ensure the
airtight sealing.
● Bring in, align and fasten the static pre-grate / the modules of the static pre-
grate.
● Successively bring in, align, bolt and fasten the preassembled modules of the
cooler in accordance with the intended arrangement.
Note
When doing so, pay attention to the provided markings on the modules.
Up to an overall cooler width of 2.5 m, the cooler is just one module wide. For
wider coolers, several modules have to be assembled side by side.
In longitudinal direction, the POLYTRACK® cooler usually consists of several
modules. The static pre-grate is also delivered in one or several preassembled
modules.
Compensate dimensional deviations in vertical direction by inserting shims
under the base plates of the grate substructure.
If there are any dimensional deviations in horizontal direction, compensate by
inserting packing plates at the ends of the module connection points. For details,
see the drawings "POLYTRACK® assembly drawing" and "Lower housing
section, site assembly" in the section Technical drawings.
The permissible misalignment between neighbouring modules in horizontal
direction and in vertical direction must not exceed the measurements stated in
the measurement record.
Be sure to mount the fishplates for connecting the longitudinal girders without
using any force. It must be possible for them to rotate freely.
Remove the transport securing devices prior to the assembly.

After completing the alignment, prepare a measurement record.
● After the assembly has been approved and released by the POLYSIUS AG
assembly supervisor, weld the modules together.
● Mount and lock the connecting fishplates (2.5) of the longitudinal girders (2.1).
Note
Make absolutely sure that the pins (2.6) are not subject to constraint and can
rotate freely.
en-PQ.CPT.001.B
®
Fig. 15: Connecting fishplate
● Mount the still missing parts of the grate equipment. Weld the pin locking
device (1.4) with heat resistant filler metal.
Fig. 16: Pin locking device of transport track
Note
All bolts for which a tightening torque has been specified must be tightened by
means of a torque wrench and only slightly oiled at threads and head contact
areas. Do not use paste or Molykote.
The mounting plate (1.3) must be in secure contact with the longitudinal girder
(2.1).
en-PQ.CPT.001.B
®
Fill the openings (S) in the corners of the front end contact surfaces between the
sealing frame (1.6) and the intermediate piece (1.9) with high-temperature-
resistant silicone sealing compound.
Intermediate piece (1.9)
Fig. 17: Intermediate piece
● Mount and weld the partitions of the lower housing section.
en-PQ.CPT.001.B
®
Fig. 18: Partitions
Note
During assembly of the upper partitions (4.20) [at the module joint], make sure
that the gap (X) between the longitudinal girder (2.1) and the partition wall (4.20)
conforms to view "Z". The gap (X) should be 3 mm!
The lower partition (4.30) is welded airtight during module construction.
● Mount and weld the side walls and end walls of the lower housing section
(4.0). Install the discharge chute.
● Insert and weld the viewports (4.10), the sealing flaps (4.11) and the door.
Install the lighting.
en-PQ.CPT.001.B
®
Sidewall
Fig. 19. Sidewall
● Mount the hydraulic cylinder (14.0), if applicable, including the travel

measuring system (14.10).
● Install, align and anchor the hydraulic unit.
● Route, adjust, align and fasten the hydraulic pipes for the cooler drive,
including the associated flexible connections.
Note
Detailed information on the assembly of the cooler drive is contained in the
separate machine manual.
● Install the roll crusher (20.0).
Note
Detailed information on the assembly of the roll crusher is contained in the
● Assemble the roll crusher drive and route, adjust, align and fasten the
hydraulic pipes, including the flexible connections.
● Mount the cooling air duct for the cross girder and the aeration piping and
exhaust air ducts for the roll crusher.
en-PQ.CPT.001.B
®
● Mount the sidewalls and end walls of the upper housing section (5.0), as well
as the girders and the cover, and weld all joints so that they are airtight. Install
the discharge chute.
● Install protective pipes for thermocouples and other instrumentation.
● Install the bullnose cooling system and the air blast units (6.0).
Note
Detailed information on the assembly of the air blast units is contained in the
● Install the refractory lining (22.0).
Note
When carrying out refractory lining work in the vicinity of the aeration units,
make sure that no mortar enters the aeration units!
You can do this by covering them with plastic sheets or tarpaulin and additional
boards. After completing the work, remove the protective covering!
When drying the refractory lining by means of additional heat input, ensure that
the temperature-sensitive components below the aeration floor are not heated
above the permissible temperature.
This applies in particular to hydraulic cylinders, hydraulic hose piping, slide
plates of the bearing assemblies, travel measuring system and connecting
cables of the travel measuring system at the transport tracks.
As a rule, the limit temperature for hydraulic system components and connecting
cables is approx. 80 °C. The slide plates (2.4) are suitable for a maximum
temperature of approx. 180 °C.
The temperature of the individual components must be monitored constantly. If
there is a danger of overheating, take suitable countermeasures such as
supplying cooling air or removing sensitive components (e.g. travel measuring
system).
● Mount the access and maintenance doors (with refractory lining).

● Mount the fans (21.0) and aeration piping including any dampers.
en-PQ.CPT.001.B
®
Air distribution diagram (1.50)
● Install the air distributors (1.51 and 1.52) and orifice plates (1.55 and 1.56) in
accordance with the air distribution diagram.
● Adjust and mount the piping for compressed air and install the thermocouples.
● Install the roll dismounting device.
en-PQ.CPT.001.B
Machine manual Lubrication
®
5 Lubrication
Note
The POLYSIUS table of lubricants with the lubricant reference numbers is
contained in the supplement Important notes on the documentation. The
supplement is contained in this folder or at the beginning of the overall
documentation. Each lubricant has a unique reference number to which the
lubrication instructions in this section relate. The table gives a complete list of all
subsuppliers and products approved by POLYSIUS AG. It is the responsibility of
the lubricant subsupplier to select appropriate lubricants corresponding to the
lubricant reference numbers. POLYSIUS AG accepts no liability for the
correctness of this data. If you wish to use a lubricant that is not included in the
Table of lubricants, you have to first obtain the express permission of POLYSIUS
AG. The supplement Important notes on the documentation also includes
general information about the lubrication.
CAUTION
Lubricants that are not properly stored, used and disposed of are an
environmental hazard.
They can harm humans, animals and plants.
Ensure that the environment is not polluted when lubricants are stored,
used and disposed of and carefully observe the relevant national
legislation for the protection of the environment when handling lubricants.
Lubrication points Quantity (l, kg) per Lubrication intervals (weeks)

lubrication point
No. Qty. Designation Lubricant Initial Topping Topping up First Further

ref. no. filling up change changes
1 Drive
See separate machine manual.
2 Roll crusher
3 Fans In accordance with the subsupplier's instructions.
The different makes of lubricants corresponding to the lubricant reference numbers are shown in the Table of
lubricants in the supplement Important notes on the documentation. The supplement is contained in this folder or at the
beginning of the overall documentation.
Tab. 1: Lubrication chart
en-PQ.CPT.001.B
Machine manual Commissioning
®
6 Commissioning
Note
It is a prerequisite of our warranty that the first test run is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.
6.1 Checks prior to the test run

After completing the assembly work and prior to the first test run, check all parts
of the plant in accordance with the list below. Make absolutely sure that all
material remnants, tools and auxiliary assembly devices have been carefully
removed.
● Have the foundations been properly grouted in?
● Have all the foundation bolts been properly tightened?
● Have all flange connections been bolted on tightly?
Have the designated seals been fitted correctly?
● Have all the aeration compartments been cleaned and are they free of tramp
material?
● Has the movability of the transport tracks and other moving parts been
checked?
All mechanical locking devices must have been removed!
● Have all bolted connections been tightened and locked in accordance with
instructions?
● Have all springs of the spring system for pressure application on the sealing
frames been correctly set (see section Transport and assembly) and have the
nuts been locked?
● Is the air piping free of tramp material and contamination?
● Can the cooling air flow freely through all the aeration units?
● Have all the covers (if used) been removed?
● Have all checks at the drive (14.0) been carried out? (See separate machine
manual.)
● Have all the checks at the fans (21.0) been carried out according to the
subsupplier's instructions?
● Has the direction of rotation of all drive motors been checked?
● Have all the bearings been supplied with grease?
● Have all checks at the roll crusher (20.0) been carried out? (See separate
machine manual.)
● Is the outward conveying equipment downstream of the clinker cooler ready
for operation?
● Have the machine interlocks been checked for proper functioning?
● Have all the monitoring devices been checked?
en-PQ.CPT.001.B
Commissioning Machine manual
®
● Have all the cables been so laid or protected that they cannot be damaged by
the opening of doors and covers or by heat radiation or hot material?
● Has the refractory lining (22.0) been installed correctly?
Have the specifications regarding expansion joints been complied with?
● Has the refractory lining of the upper housing section been checked?
There must be sufficient space for the heat expansion of the kiln!
● Have all remnants of mortar interfering with the functioning of the clinker
cooler been removed?
● Have all doors and inspection ports (9.0) been tightly closed?
● Have all protection devices and warning signs been correctly mounted?
6.2 Test run

Note
After completing the checks, carry out a 24-hour test run of the clinker cooler.
If any faults are found, the test run must be interrupted and resumed after the
faults have been eliminated. After successful completion of the test run, the
clinker cooler is ready for operation.
en-PQ.CPT.001.B
Machine manual Commissioning
®
6.3 Drying the refractory lining

Drying of the refractory lining and heating-up of the plant must be carried out in
accordance with the relevant instructions of the refractories' subsupplier and the
Polysius operating manual.
When drying the refractory lining by means of additional heat input, ensure that
the temperature-sensitive components below the aeration floor are not heated
above the permissible temperature. This applies in particular to hydraulic
cylinders, hydraulic hose piping, slide plates of the bearings, travel measuring
system and connecting cables of the travel measuring system at the transport
tracks.
As a rule, the limit temperature for hydraulic system components and connecting
cables is approx. 80 °C. The slide plates (2.4) are suitable for a maximum
temperature of approx. 180 °C.
The temperature of the individual components must be monitored constantly. If
there is a danger of overheating, take suitable countermeasures such as
supplying cooling air, covering the grate (insulation matting) or removing sensitive
components (e.g. travel measuring system).
6.4 Setting and adjustment

● Calibrate the thermocouples (10.1).
Alarm values: see the section Technical data
● Readjust the spring system (1.7) of the seals.
For details, see the section Transport and assembly.
If you hear knocking noises during the test run, even after lengthy operation of
the transport tracks, the cause may be incorrect setting of the spring system.
You must then establish and locate the exact cause and eliminate it by
readjusting the springs.
As a rule, it is necessary in such cases to increase the spring tension of the
horizontal spring system (1.7.2).
en-PQ.CPT.001.B
Machine manual Operation
®
7 Operation
7.1 Operation
If kiln operation is interrupted, make sure that the clinker cooler remains in
operation as long as the rotary kiln is still discharging material to be cooled.
Adjust the stroke frequency to suit the decreasing quantity of incoming material.
Never allow the cooler to run until it is empty, except as preparation for the
performance of repair work. In addition, suitably throttle the cooling air flow to
prevent heavy dust formation.
A minimum pressure below the aeration floor is necessary for operation of the
cooler. For further information, refer to the operating manual.
Never shut down the fans until the transport tracks have been stopped and the
material on the aeration floor has sufficiently cooled down. The aeration floor
could otherwise be damaged.
If the clinker cooler was emptied for repair work, restart the plant as described in
the section Starting up.
Normally, more air is heated during the cooling process than is required by the
rotary kiln for secondary air, tertiary air and/or utility air. The excess air is
discharged from the clinker cooler through an exhaust air duct connected to the
upper housing section.
en-PQ.CPT.001.B
Operation Machine manual
®
7.2 Starting up
After drying the refractory lining and before starting the cooler, fill the static pre-
grate between the HORSE SHOE (1.30) with cold pyroprocessed material up to a
height of approximately 500 mm (measured from the aeration unit up to the upper
edge of the bed of clinker). Do the same with the first module (approx. 5000 mm).
This layer of cold material protects the aeration units against overheating and
protects the concrete of the HORSE SHOE against heating up too quickly. Keep
the transport tracks at a standstill until a sufficiently high layer of material to be
cooled has built up. As more material flows in and builds up, start the cooler grate
– initially using a low stroke frequency – in order to distribute the pile of material
away from the cooler inlet. Then stop the transport tracks again until a sufficient
quantity of hot material from the kiln has been discharged onto the cooler. Repeat
this procedure until the aeration floor and the transport tracks are completely
covered with material to be cooled.
A minimum pressure below the aeration floor is necessary for starting the cooler.
If this pressure is not reached, tightness of the aeration floor is not ensured. For
further information, refer to the operating manual.
Note
Make absolutely sure that the aeration floor is always covered with a sufficiently
high material layer (more than 500 mm measured from the aeration unit)!
During the first starting period, the secondary air consumption is so low that you
can throttle down the fans for the first chambers. As the kiln output increases,
switch on the other fans one after the other. When you switch on the fans, make
sure that all throttle devices are closed.
In order to prevent damage, take special care that the transport tracks do not
overheat when starting up the cooler. The temperature of the transport tracks
must be monitored. The alarm temperature is stated in the section Technical data.
If the supplied air flow rate is not sufficient to keep the transport track temperature
below the alarm temperature, you have to increase the air supply by increasing
the motor speed for the fans or by opening the throttle devices. The cooling air
not required for the rotary kiln is then discharged into the atmosphere through the
exhaust air duct socket (5.1).
As the quantity of material to be cooled increases, raise the cooling air flow rate
accordingly until adequate cooling is achieved. You must adjust the forward
stroke speed to the incoming quantity of material to be cooled.
The depth of the bed of cooling material on the aeration floor thus depends both
on the incoming material quantity and on the stroke frequency of the transport
tracks.
Always control the clinker cooler manually during the starting up phase. Do not
switch on the automatic control system until the normal operating state has been
attained.
Under normal circumstances, the compartment pressure of one of the front
cooling air compartments is used for controlling the stroke frequency. Alternatively
the hydraulic drive pressure can be used for control purposes.
There is also the option to install a clinker bed depth measuring device.
en-PQ.CPT.001.B
Machine manual Operation
®
7.3 Shutting down

If the rotary kiln is stopped or shut down, make absolutely sure that the cooler is
not shut down until the rotary kiln stops discharging material into the cooler. Make
absolutely sure that the aeration floor always remains covered with material.
Adjust the stroke frequency to suit the decreasing quantity of incoming material.
The roll crusher must be operated until it is empty to prevent unilateral
overheating and consequent distortion of the rolls. The subsequent zones of the
cooler, as well as the conveyors, therefore have to continue operating, possibly
with interruptions. Note that the rotary kiln can also discharge material to be
cooled while it is being turned until cold and inched. If this happens, you must
switch the clinker cooler on again for a short time.
You must throttle the fans relative to the reduced cooling air requirement, but only
to a degree which still ensures that the transport tracks are not damaged by
overheating. Be sure to close the throttle devices before the fans are stopped.
However, a specific compartment pressure is still required to ensure effective
sealing of the grate equipment.
en-PQ.CPT.001.B
Machine manual Maintenance
®
8 Maintenance
8.1 Safety instructions

DANGER
There is a risk of raw meal flushing into the clinker cooler.
You could be buried alive or sink into the material.
I. Access to the cooler must not be possible as long as cleaning work is
being performed in the preheater.
II. The plant manager must take precautionary measures to ensure safety
of the maintenance personnel.
DANGER
When automatic air blast units are used after the electricity supply has
been switched off.
Danger of unintentional shooting, due to residual pressure.
Let the residual pressure escape before opening the doors and/or poke
holes.
DANGER
Clinker or parts of the refractory lining may fall down or give way in the
clinker cooler.
I. Make absolutely sure that there are no clinker incrustations or parts of
the refractory lining that could fall down in the cooler and in the kiln
hood.
II. Make absolutely sure that all clinker / lining parts have a sufficient load
bearing capacity.
DANGER
There are hot gases inside the cooler.
There is mortal danger.
I. Make absolutely sure that there are no remaining hot gases in the
cooler and that no hot gases can enter the interior.
II. Wear the prescribed protective clothing.
III. Wait until the cooler has cooled down before starting the maintenance
work.
en-PQ.CPT.001.B
Maintenance Machine manual
®
WARNING
The machine is hot.
You could be seriously injured.
I. Wear the prescribed protective clothing.
II. Wait until the cooler has cooled down before starting the maintenance
work.
WARNING
There are rotating / moving components in / on the machine.
You could suffer severe injuries.
Do not enter the machine during operation of the machine.
WARNING
When inspection ports are opened, hot material may spatter out.
Wear the proper protective clothing and keep emergency escape routes
free.
WARNING
Open doors can move suddenly and without warning.
You might be crushed.
Secure open doors against unintentional closing.
WARNING
The noise level in the machine building can exceed 90 dB(A).
Your hearing could be harmed.
Wear hearing protectors.
Note
After you have completed the repair work, you must check the machine/plant
again in accordance with the section Preparation for test run.
en-PQ.CPT.001.B
®
8.2 Inspection
8.2.1 Inspection during operation
No. Work to be performed Frequency Comments
1 General visual inspection for leaks Daily
Check the viewports and the lighting Daily The glass panes of the
viewports in the hot zone
must not have any
cracks; check the lighting
2 from outside through the
viewports (defective
lamps can be changed
while the cooler is
operating).
Check the aeration compartments to Daily

3
see if any clinker is falling into them
Check the upper housing section (5.0) Daily Cause: damage to the
4
for local thermal deformations. refractory lining
Check the measuring, control and Weekly

5 monitoring devices for proper
functioning and cleanliness.
Check the slide plates for wear Monthly There are wear markers
visible from the outside,
6
see the section
Maintenance.
Check the fans (21.0) In accordance with the

7
subsupplier's instructions
Check the drive (14.0) See separate machine

8
manual.
en-PQ.CPT.001.B
®
8.2.2 Inspection during stoppage of the kiln plant
Check for cracks and wear of the Annually

1 ● Transport tracks
● bolts of transport tracks
Check for wear of: Annually

2
● aeration units

3 ● nozzles of the air blast units in the
static grate, end walls and sidewalls

4 ● slide plates
● slide rails
5 Check the sliding seals for wear. Annually
Check the refractory lining (22.0) for Annually

6
damage
Check the roll crusher (20.0) See separate machine

7
manual.
en-PQ.CPT.001.B
®
8.3 Servicing
1 Repair any leaks As required

● at doors
● at flange connections
● at the housing
2 Replace defective transport tracks As required
3 Replace defective bolts of transport tracks As required
4 Replace faulty aeration units As required
5 Replace faulty air blast unit nozzles As required
6 Replace worn As required

● slide plates
● slide rails
7 Replace worn As required Wear > 1 mm

● sliding seals
8 Replace any damaged parts of the refractory lining As required In accordance

(22.0) with the
subsupplier's
instructions
9 Maintenance work on the drive (14.0) See separate

machine
manual
10 Maintenance work on the roll crusher (20.0) See separate

machine
manual
11 Maintenance work on the fans (21.0) See

subsupplier's
information
12 Clean the glass windows of the viewports from inside Annually
13 Replace any worn seals at doors and inspection ports As required

(9.0)
en-PQ.CPT.001.B
®
14 Replace any defective light bulbs of the lighting system As required Replacement
is also
possible
during
operation, see
the section
Transport and
assembly
(figure
Lighting)
en-PQ.CPT.001.B
®
8.4 Repair
If damage is found during the checks described in the sections Inspection and
Maintenance, you must repair the damaged parts or replace them with new parts.
Required personnel
To ensure correct performance of the work, it is important that all the assigned
personnel have received special training for the tasks to be performed.
Note
We recommend having the repair work carried out under the supervision of an
expert from POLYSIUS AG.
Required tools
It is a prerequisite for the correct performance of the work that all tools and
appliances are carefully selected.
No special tools are required. However, you may need torque wrenches of a
bigger size than normal and suitable hydraulic pumps.
Whether or not you need auxiliary equipment, such as scaffolds or auxiliary
supports, depends on the operating conditions in your plant.
General
The basic safety instructions must be complied with. Also refer to the section
Safety.
Switch off the power supply to all electrical components before beginning any
repair work.
Ensure absolute cleanliness at all times during the repair work in order to prevent
dirt from entering the bearings, the drives, hydraulic systems or other sensitive
parts of the machine or plant.
Do not remove or open any covers or protection devices before all rotating parts
have come to a complete standstill.
Note
The following repair instructions do not detail the individual steps, but rather give
an overview of the work to be performed.
en-PQ.CPT.001.B
®
8.4.1 The following repair work is described or mentioned:
1. Replacing components of the static pre-grate

● aeration units (1.21)
● nozzles (1.24) for air blast unit
● protective plates (1.27)
● HORSE SHOE (1.30) brickwork
● front plates (1.11)
2. Replacing components of the grate equipment
● transport track (1.1)
● aeration units (1.2)
● mounting plate (1.3) for transport track (with sealing surface)
● sealing frame (1.6)
● spring system (1.7)
3. Replacing components of the longitudinal girders and the bearing assembly
● slide rail (2.2)
● slide plate holder (2.3.2)
● slide plate (2.4)
● bearing block (2.3)
● fishplate (2.5), longitudinal girder, pin (2.6), longitudinal girder
4. Replacing components of the temperature measurement system at the
transport tracks
● Thermocouple (10.1)
5. Replacing components of the aeration system
● air distributors (ADS) (1.51, 1.52)
● orifice plates (1.55, 1.56)
en-PQ.CPT.001.B
®
8.4.2 Replacing aeration units of the static grate
1.21.1 Aeration unit 498 x 300
1.21.2 Aeration unit 248 x 300
1.21.3 Aeration unit with nozzle 498 x 300
1.21.4 Aeration unit after nozzle 498 x 300
1.21.5 Bolted connections of aeration unit
1.22.1 Internal part of aeration unit 498 x 300
1.22.2 Internal part of aeration unit 248 x 300
1.22.3 Internal part of aeration unit with nozzle 498 x 300
1.22.4 Internal part of aeration unit after nozzle 498 x 300
1.23 Cover plate
1.24.5 Connecting bolts of nozzle
1.29.1 Connections for air distributors 140 x 140 (air nozzle)
1.29.2 Connections for air distributors 54 x 150 (sides in the

end grate zone)
1.29.5 Connecting bolts of the connecting sleeve (1.29.1)
1.29.6 Connecting bolts of the connecting sleeve (1.29.2)
Fig. 21: Static grate
en-PQ.CPT.001.B
®
Static grate
Fig. 22: Static grate
en-PQ.CPT.001.B
®
Step 1: To replace the aeration units (1.21.1 and 1.21.2), aeration units with nozzle
(1.21.3), and the aeration units after the nozzle (1.21.4), unscrew the four
bolted connections (1.21.5).
Depending on the condition of the components, you can or must replace either
only the internal part 1.22.1‚ 1.22.2, 1.22.3 or 1.22.4) or the entire aeration unit
(1.21.1, 1.21.2, 1.21.3, or 1.21.4).
If only the internal part is to be replaced, no further bolted connections need to be
undone.
Step 2: If it is necessary to replace the entire aeration unit, you will first have to
dismount the air distributors (1.51, 1.52) that are installed underneath some
of the aeration units (1.21.1, 1.21.2, 1.21.3 or 1.21.4) in order to facilitate
dismounting of the aeration units.
2.1 In aeration units with a nozzle (1.21.3), you will additionally have to
dismount the connections for the air distributors (1.29.1) by unscrewing
the connecting bolts (1.29.5). You will also need to unscrew the
connecting bolts (1.24.5) to the nozzle.
2.2 You can dismount the nozzles of the air blast unit (1.24) after unscrewing
the connecting bolts (1.24.5).
Step 3: In the aeration units (1.21.2) in the end zone of the grate, the air distributor
connections (1.29.2) are each joined to the aeration unit by 2 connecting
bolts (1.29.6). Lift the connection (1.29.2) and withdraw the connecting bolts
(1.29.6) to the side. You can then remove the connection (1.29.2) in a
downward direction.
If an elastic sealing compound was used for sealing the aeration units at the
girder, you may have to use extra force to detach them.
Step 4: To install the new aeration units, including the other dismounted parts,
reverse the above sequence of work analogously.
Be sure to retighten the bolted connections with the stipulated bolt tightening
torque.
If the condition of the air blast unit nozzles (1.24) makes it necessary, you should
also replace them while carrying out this work. For a description of the work
involved, refer to the point Replacing the nozzles of the air blast unit in this
section.
en-PQ.CPT.001.B
®
8.4.3 Replacing the nozzles of the air blast unit
Step 1: In order to dismount the nozzles of the air blast units (1.24), you must
unscrew and remove the bolted connections (1.24.5).
Step 2: Remove the nozzles in upward direction.
Step 3: Install analogously in reverse order to the disassembly.
Be sure to retighten the connecting bolts (1.24.5) with the stipulated tightening
torque.
Fig. 23: Aeration unit with nozzle
It is possible to alter the position of the nozzles in face width direction if this is
necessary for process technological reasons.
For this purpose, you must change the position of both the aeration units with
nozzles (1.21.3) and the aeration units after the nozzle (1.21.4). You will need to
correspondingly modify the connections for the air distributors (1.29.1) and the
connecting sleeve for the nozzle (1.28).
Replace the aeration units as described above. The girders (1.25) are already
provided with the required holes.
Step 4: Inspect the air pipes from the air blast unit to the aeration unit after nozzle
(1.21.4) for leaks, in particular at the pipe bends.
en-PQ.CPT.001.B
®
8.4.4 Repairing the HORSE SHOE brickwork
Repair any worn out or broken off parts of the horseshoe (1.30) in accordance with
the instructions given by the refractories supplier.
If the shape of the horseshoe (1.30) has to be changed for process technological
reasons, you may also have to alter the positions of the air blast unit nozzles
(1.24). See the point Replacing the nozzles of the air blast units (1.24).
en-PQ.CPT.001.B
®
8.4.5 Replacing the transport tracks
The transport tracks installed in different zones of the cooler may be different in
shape.
Make absolutely sure that the new transport tracks are of the same shape as the
original transport tracks.
Deviations from this are only permissible after prior consultation with POLYSIUS
AG.
With the exception of the transport tracks at the end of an aeration floor, each
transport track is attached by two pins. One drill hole of the mounting plate (1.3)
is cylindrical and one is oblong. This enables unhindered thermal expansion of
the transport tracks.
Note
In the case of transport tracks (1.1) which are provided with a thermocouple
(10.1) for temperature measurement, you must first dismount the thermocouple.
For this purpose, see the corresponding detailed description.
Step 1: Remove the pins (1.4).

These pins are secured by welded-on discs (1.4.1).
1.1 To detach the discs, you must remove the weld (1.4.2) by flame cutting or
flame grooving.
Fig. 24: Removal of the pins
If you select the flame cutting method, you must take into account the fact that
the pins (1.4) are made of heat resistant steel.
If the pins cannot be driven through the drilled holes in the transport track (1.1)
and the mounting plates (1.3) by means of light hammer blows (it is helpful to
apply a spray lubricant to reduce the friction), you will have to pull them out, for
instance with the aid of a threaded rod welded onto the head of the pin and a
suitable device braced against the same transport track.
en-PQ.CPT.001.B
®
1.2 Alternatively, you can first open up a gap between the head of the pin and
the metal surface beneath the head by means of light hammer blows on
the pin and then insert wedges to move the pins.
Note
It is not permitted to knock out or force out the pins by means of heavy blows or
by using mounting jacks braced against the sidewall of the upper section of the
cooler or against a neighbouring transport track.
This could damage components of the bearing assembly.
Step 2: To install the new transport tracks (1.1) and the parts of the associated pins
(1.4, 1.4.1, 1.4.2), reverse the above sequence of work analogously.
Note
Make absolutely sure that the direction of installation of the transport tracks is
correct.
Also see the instructions in the section Transport and Assembly, subsection
Sequence of assembly.
Step 3: If you previously dismounted any thermocouples (10.1), you must now
reinstall them.
en-PQ.CPT.001.B
®
8.4.6 Replacing aeration units
Without dismounting the transport tracks (1.1), mounting plates (1.3) and sealing
frames (1.6), you can only remove or replace the inner part (1.2.1) of the aeration
unit.
To facilitate the dismounting of the entire aeration unit, you will also have to
dismount any installed air distributors (1.51, 1.52) or orifice plates (1.55, 1.56)
that are mounted underneath the aeration units.
In the connection zone of two module widths and in the edge zones of the cooler,
aeration units of half the normal width and with special air inlet openings are
installed.
In these zones, air distributors(1.52) with sockets (1.52.1) or with orifice plates
(1.56) may be installed.
Be sure to take this into account when allocating the spare parts for the
replacement.
Fig. 25: Aeration unit
Step 1: Unscrew and remove the four bolted connections (1.2.5).

Step 2: To install the new aeration units, if necessary including the other previously
dismounted parts, reverse the above sequence of work analogously.
Be sure to retighten the bolted connections (1.2.5) with the stipulated tightening
torque.
en-PQ.CPT.001.B
®
8.4.7 Replacing transport track mounting plates
Fig. 26
Step 1: Dismount the transport tracks (1.1) that are installed above the mounting
plates (1.3).
Step 2: In the case of transport tracks (1.1) which are provided with a thermocouple
(10.1) for temperature measurement, you must first dismount the
thermocouple.
Step 3: Unscrew and remove the bolted connections (1.3.5) of the mounting plates
(1.3).
The mounting plates are bolted on between the angle brackets (1.5).
3.1 Unscrew and remove one of the bolted connections (1.5.5).
Note
One of these angle brackets is secured in position on the longitudinal girder
(2.1) by dowel pins (1.5.6). You must not detach this angle bracket, as otherwise
it would be necessary to realign the mounting plates.
Step 4: To install the new mounting plates (1.3) and transport tracks (1.1), reverse
the above sequence of work analogously.
4.1 Be sure to retighten the bolted connections with the stipulated tightening
torque.
4.2 If you previously dismounted any thermocouples (10.1), you must now
reinstall them.
en-PQ.CPT.001.B
®
8.4.8 Replacing sealing frames
Note that the sealing frames are clamped in by the horizontal spring system
(1.7.2) in longitudinal direction.
To facilitate dismounting, we recommend relieving the spring tension of the
horizontal spring system (1.7.2). After completing the work, you have to reset the
springs to the same tension.
For this purpose, see the corresponding detailed description (Spring system).
Fig. 27: Sealing frame
Step 1: Dismount the transport tracks (1.1) and mounting plates (1.3) that are
installed above the sealing frame (1.6).
Step 2: Remove the sealing frame (1.6) in an upward direction.
Step 3: To install the new sealing frames, including the other dismounted parts,
reverse the above sequence of work analogously.
3.1 Do not forget to install the thrust elements (1.6.1).
torque.
Step 4: After installing the sealing frames, you must seal the openings in
accordance with the instructions given in the section Transport and
Assembly, subsection Sequence of assembly.
en-PQ.CPT.001.B
®
8.4.9 Replacing the spring system
It is possible to replace some of the spring systems (1.7) or parts of them from
below, working from the cooling air compartment.
However, it is easier to replace parts of the horizontal spring system (1.7.2) from
above after dismounting the sealing frame (1.6).
As a rule, it is not necessary to replace the spring systems.
Step 1: Before dismounting parts of the spring system, be absolutely sure to make
a written record of the preloading condition of the individual springs.
This is required in order to readjust the springs to the same preloading condition
after reassembly. A measure of the preloading is the position of the adjusting nuts
(1.7.13 and 1.7.23) or the projecting length of the threaded bolts (1.7.12 and
1.7.22).
Step 2: You can determine the work operations required for the dismounting and
installation on the basis of the following diagrams.
For details see the figure "Spring system" and the drawing "Spring system" in the
section Technical drawings.
en-PQ.CPT.001.B
®
Step 3: Be absolutely sure to carry out any adjustment of the spring systems in
accordance with the specifications in the sections Commissioning and
Settings and Adjustment.
Step 4: Secure the settings by careful locking of the nuts.
en-PQ.CPT.001.B
®
8.4.10 Replacing the slide rails
The replacement of slide rails (2.2) must always be seen in connection with the
replacement of slide plates (2.4) and slide plate holders (2.3.2).
The condition of the parts determines whether it is necessary when replacing the
slide rails (2.2) to also replace the respective slide plates (2.4) and, the other way
around, whether it is necessary when replacing the slide plates to also replace
the respective slide rails.
As a rule it is good policy when replacing slide rails to also replace the associated
slide plates.
The condition of slide rails (2.2.1, 2.2.2, 2.2.3) and slide plates (2.4.1, 2.4.2,
2.4.3) that are installed at different locations in the cooler can be different, even
though they have reached the same operating time.
In order to make a wear prediction, you need to know when the respective slide
rail (2.2) was replaced or turned over. This information in combination with the
determined wear allows you to draw conclusions about how long it will take for
the depth of wear on the slide rail to reach the limit value of 1 mm.
The slide rail (2.2) has to be regarded as worn out and must be replaced when
the sliding surface shows a wear depth of 1 mm or is damaged [e.g. irregular
undulating wear]. When the specified wear depth (Y) of 1 mm has been reached,
the slide rail (2.2) can be turned over and the reverse side can then be used as
the sliding surface. This is subject to the precondition that the opposite side has
not suffered any damage and does not show signs of serious wear. The turned-
over slide rail (2.2) must be permanently and clearly marked, so that the need for
spare parts can be determined in good time during inspections.
Fig. 30: Example for worn-out slide rails
en-PQ.CPT.001.B
®
Step 1: Position the respective longitudinal girder (2.1) so that the bolted
connections (2.2.1.5, 2.2.2.5, 2.2.3.5) are accessible.
1.1 To permit dismounting of the upper slide rails (2.2.1), you must raise and
support the longitudinal girders (2.1) so that the respective slide rail is
relieved of load.
Step 2: Unscrew and remove the bolted connections (2.2.1.5, 2.2.2.5, 2.2.3.5).
The self-locking nuts (2.2.1.7, 2.2.2.7, 2.2.3.7) of the bolted connections have a
metallic locking element. Every time the bolted connections are unscrewed and
subsequently retightened, the locking effect is reduced. In order to ensure that
the bolts are reliably secured against loosening during operation, you must install
new nuts after a maximum of 3 replacements.
Step 3: Remove the respective upper slide rails (2.2.1), middle slide rails (2.2.2) or
lower slide rails (2.2.3).
The middle slide rails (2.2.2) are attached to the bolted connections (2.2.2.5) in
pairs.
Step 4: To install the new slide rails, reverse the above sequence of work
analogously.
Make sure that the contact surfaces of the new slide rails (surface in contact with
the slide plate) are free of damage.
Be sure to retighten the bolted connections with the stipulated tightening torque.
Fig. 31: Sliding bearing arrangement
en-PQ.CPT.001.B
®
8.4.11 Replacing the slide plate holders
The replacement of slide plate holders (2.3.2) must always be seen in connection
with the replacement of slide rails (2.2) and slide plates (2.4).
To replace the slide plates (2.4) it is always necessary to dismount the slide plate
holders (2.3.2).
You must decide on the basis of the condition of the components whether or not
you should also replace the associated slide rails (2.2) when changing the slide
plate holders (2.3.2) including slide plates (2.4).
As a rule it is good policy when replacing slide rails (2.2) to also replace the
associated slide plates (2.4).
The condition of slide plates (2.4) and slide rails (2.2) that are installed at different
locations in the cooler can be different, even though they have reached the same
operating time.
To speed up the replacement work, you can also prepare slide plate holders
(2.3.2) in advance, by completely fitting them with new slide plates (2.4).
Note
Dismounting of the complete bearing blocks (2.3) is only necessary in
exceptional cases. Before dismounting bearing blocks, you must make certain
preparations.
When doing so, be sure to comply with the corresponding instructions.
Step 1: Move the respective longitudinal girder (2.1) into an end-of-stroke position.
You can do this by using the local control panel of the drive.
Step 2: Raise and support the longitudinal girders (2.1) so that the respective
bearing point is relieved of load.
To do this, you can use mechanical lifting spindles or hydraulic lifting jacks.
You should support the girders on the cross girder of the grate substructure (3.0).
Step 3: Unscrew the bolted connections (2.3.3).
Step 4: Remove the slide plate holders (2.3.2) in the cooler's longitudinal direction.
en-PQ.CPT.001.B
®
Step 5: To install the new slide plate holders (2.3.2), reverse the above sequence of
work analogously.
Make absolutely sure that the contact surfaces between the slide plate holders
(2.3.2) and the basic body (2.3.1) are undamaged and clean.
Be sure to retighten the bolted connections (2.3.3) with the stipulated tightening
torque. Do not lubricate the threads.
Fig. 32: Sliding bearing arrangement
en-PQ.CPT.001.B
®
8.4.12 Replacing slide plates
The replacement of slide plates (2.4) must always be seen in connection with the
replacement of slide plate holders (2.3.2) and slide rails (2.2).
To replace the slide plates (2.4) it is always necessary to dismount the slide plate
holders (2.3.2).
Be sure to replace the slide plate holders (2.3.2) in accordance with the special
description for the replacement of slide plate holders (2.3.2).
You must decide on the basis of the condition of the components whether or not
you should also replace the associated slide rails (2.2) when changing the slide
plates (2.4). As a rule it is good policy when replacing slide rails (2.2) to also
replace the associated slide plates (2.4).
The condition of slide plates (2.4) and slide rails (2.2) that are installed at different
locations in the cooler can be different, even though they have reached the same
operating time.
In order to make a wear prediction, you need to know when the respective slide
plate (2.4) was replaced. This information in combination with the determined
wear allows you to draw conclusions about how long it will take for the slide plate
wear marker (X) to wear down from the initial 2.5 mm to 1 mm.
Fig. 33: Slide plate wear marker
You can assess the wear condition of the slide plates (2.4) on the basis of the
wear markers that are machined into the plates. Wear is permitted up to a
maximum of 2.5 mm. This corresponds to the depth of the marker (X).
In the case of the bearing blocks (2.3) of the outer transport tracks, you can
monitor these markers from outside the cooler, even while it is in operation.
You must always replace the upper and/or lower slide plates (2.4) of each bearing
point in pairs. Also, you must always replace the slide plates (2.4) of both bearing
blocks (2.3) of each track and module together.
en-PQ.CPT.001.B
®
Note
Dismounting of the complete bearing blocks (2.3) is only necessary in
exceptional cases. Before dismounting bearing blocks, you must make certain
preparations.
When doing so, be sure to comply with the corresponding instructions.
Step 1: Unscrew the fastening bolts (2.4.5).
Note
If you try to unscrew the bolts with an impermissibly high torque, they will be
destroyed and a costly and time-consuming repair of the connection will be
necessary. If you have to heat up the components in order to loosen them, you
need not worry about damaging the old slide plates (2.4), as these will not be
reused.
When the fastening bolts (of the slide plates (2.4) were screwed into the slide
plate holder (2.3.2), they were bonded in place with a chemical nut locking agent.
As a rule, you should be able to unscrew the bolts by applying a suitably high
torque.
If you are unable to unscrew these bolts with the maximum permissible torque
(approx. 50 Nm), you will have to heat the bolted connection up to approx. 250 C
and then have another try at unscrewing them.
Step 2: Remove the slide plates (2.4).
Step 3: Remove any remainder of the old nut-locking agent from the contact
surfaces and threads of the slide plate holder (2.3.2).
Step 4: Mount the new slide plates (2.4).
en-PQ.CPT.001.B
®
Step 5: Fasten by means of the fastening bolts (2.4.5).

5.1 Clean the contact surfaces of the fastening bolts (2.4.5) with a special
cleaner.
5.2 You must apply chemical nut locking agent of the type "medium-strong" in
accordance with the manufacturer's instructions.
torque.
Note that the middle bolt has to be tightened with a higher torque.
Fig. 34
en-PQ.CPT.001.B
®
8.4.13 Replacing the bearing blocks
Replacement or dismounting of the bearing blocks (2.3) is only necessary in

exceptional cases.
In order to ensure correct reassembly, you have to carry out certain preparatory
steps before dismounting the bearing blocks (2.3).
Be sure to perform the following work steps:
Step 1: To prepare for dismounting the bearing blocks (2.3), you must move the
respective longitudinal girder (2.1) into its middle-of-stroke position.
You can do this by using the local control panel of the drive.
Step 2: Before dismounting the bearing blocks (2.3), you must raise and support
the longitudinal girders (2.1) so that the respective bearing point is relieved
of load.
To do this, you can use mechanical lifting spindles or hydraulic lifting jacks. You
should support the girders on the cross girder of the grate substructure (3.0).
Step 3: When doing so, align the position of the longitudinal girder (2.1) in the
direction of the cooler width so that before the bolted connections (2.3.51
and 2.3.52) of the bearing blocks are undone the distances between the
vertical surfaces of the middle slide rails (2.2.2) at the bolted connections
(2.2.25) and the vertical, machined surfaces of the bearing block body
(2.3.1) and/or the slide plate holder (2.3.2) are equal on both sides.
Take suitable measures to fix the component in this position.
Make a written record of the measurements of the position.
As an alternative to this method, you can also attach a secure stop on both sides
of the cross girder (3.0) for the inner, vertical machined surfaces of the bearing
block body (2.3.1).
Step 4: After unscrewing and removing the bolted connections (2.3.10.1, 2.3.10.2),
you can dismount the bearing blocks (2.3).
Depending on the installation position of the respective bearing block, you will
have to move it in a transverse and/or lengthwise direction in order to dismount it.
The self-locking nuts (2.3.10.3, 2.3.10.4) of the bolted connections have a
metallic locking element. Every time the bolted connections are unscrewed and
subsequently retightened, the locking effect is reduced. In order to ensure that
the bolts are reliably secured against loosening during operation, you must install
new nuts after a maximum of 3 replacements.
en-PQ.CPT.001.B
®
Step 5: To install the new bearing blocks (2.3), reverse the above sequence of work
analogously.
When doing this, take care that they are aligned in accordance with the
previously recorded measurements or the attached stops. This is the only way to
ensure that the longitudinal girders (2.1) are positioned identically to their original
location.
5.1 In the case of new slide plates (2.4) and slide rails (2.2), make sure that
there is a vertical gap of 0.25 mm on both sides of the middle bearing
assembly. Make absolutely sure that the contact surfaces of the slide rails
(2.2) (surfaces in contact with the slide plate) are free of damage.
torque (see section Technical data).
Due to the tight space conditions, the use of a hydraulic bolt pretensioning device
is recommendable.
Make absolutely sure that there is an adequately large clearance between the
bolted connections (2.2.3.5) of the slide rails and the bolted connections
(2.3.10.2) of the bearing blocks in vertical direction during the movement of the
longitudinal girders. In this respect, take into consideration that at maximum
permissible wear of the slide plates the longitudinal girder can be approx. 2.5 mm
lower.
Fig. 35:
en-PQ.CPT.001.B
®
8.4.14 Replacing the fishplates and pins of the longitudinal girder
Step 1. Unscrew and remove the bolted connections (2.6.5).

Before you can do this, you have to remove the locking washer (2.6.51).
Step 2: Remove the pins (2.6) and fishplates (2.5).
Step 3: Before fitting the fishplates and pins, you must inspect the drill hole on the
longitudinal girder (2.1) for damage. Any necessary measures for
elimination of damage must be agreed with POLYSIUS AG.
Step 4: Coat the contact surfaces of the connection of the longitudinal girder (2.1),
of the pin (2.6), of the pin disc (2.6.1) and of the fishplates (2.5) with a
suitable lubricant before assembly.
Step 5. After you have installed the bolted connections (2.6.5), including the
locking washer (2.6.51), the pin unit must still have some clearance in the
axial direction.
The pin must be able to turn freely and the fishplates must not be constrained
due to overtightening of the pin.
Step 6: Finally, you must bend up the ends of the locking washer (2.6.51) in order to
secure the bolted connection (2.6.5) to the bolt heads.
Fig. 36: Connecting fishplate
en-PQ.CPT.001.B
®
8.4.15 Replacing the thermocouples for temperature measurement on the transport

tracks
If proper functioning of thermocouples (10.1) is no longer assured, they have to

be replaced.
The thermocouples also have to be removed and later reinstalled whenever
transport tracks (1.1) or fastening and sealing elements are replaced.
Step 1: Detach the clamp of the connecting cable (10.3) on the longitudinal girder
(2.1) and pull the connecting cable so far out of the protective pipe (10.4)
that it allows sufficient freedom of movement for withdrawing the
thermocouple.
Depending on the position of the thermocouple and of the longitudinal girder, you
may have to move the affected transport track in order to improve accessibility.
Step 2: Detach the retaining element (10.2) and then pull the thermocouple
downward with a slight rotary motion.
Step 3: To install the new transport tracks, reverse the above sequence of work
analogously.
3.1 Before inserting the thermocouple, completely clear out the drill hole in the
longitudinal girder (2.1), in the mounting plate (1.3) and in the transport
track (1.1).
Step 4: Make absolutely sure that the spring measuring head of the thermocouple
is in contact with the measuring point (10.10) in the transport track and that
the spring protective pipe of the thermocouple is pressed against the
transport track.
If this is not the case, reliable measurement is not assured.
en-PQ.CPT.001.B
®
en-PQ.CPT.001.B
®
8.4.16 Replacing the air distributors and orifice plates
Required personnel
Replacing air distributors and orifice plates requires at least two persons for work
in the air compartments.
It may become necessary to replace air distributors (1.51, 1.52) and orifice plates
(1.55, 1.56) or parts thereof if the process technological conditions of the cooler
are changed.
Normally, the optimum outfitting of the cooler with air distributors and orifice
plates is determined during commissioning. See the current version of the
drawing "Air distribution diagram" provided in the appendix.
Any change made to the configuration must have the prior consent of POLYSIUS
AG and must be documented.
As a rule, it is not necessary to replace these devices because of wear or other

damage.
One must distinguish between the replacement of entire units and the
replacement of component parts thereof.
As shown in the following figures, different air distributors (1.51, 1.52) and orifice
plates (1.55, 1.56) are installed underneath the aeration units (1.2).
Step 1: To dismount the air distributors (1.51), you must unscrew the bolted
connections (1.51.5) and release and remove the folding connector (1.51.6)
by folding over the ring (1.51.7). You can then remove the air distributors by
shifting them in longitudinal direction of the cooler.
Note that the entire weight of the switch (max. approx. 10 kg) has to be supported
during its removal.
en-PQ.CPT.001.B
®
1.1 You can adapt the air distributors to the process technological
requirements by exchanging the pendulum counterweights (1.51.2,
1.52.2).
The various pendulum counterweights that can be used differ in weight, due to
different thicknesses. The different pendulum counterweight versions are
identified by punched-in numbers (thickness of the pendulum counterweight in
mm) and by different colours (for their allocation see the drawing "Air distribution
plan"). The thickness of the pendulum counterweight is the basis for the
designation shown in the air distribution diagram.
If you have to replace an air distributor (1.51), you can do so when the unit is
installed in the cooler or when it has been removed.
1.2 To replace a pendulum counterweight (1.51.2), first remove one of the
spring cotters (1.51.8) and then pull out the pin (1.51.3). You can then
remove the pendulum counterweight.
1.3 Install analogously in reverse order to the dismounting.
1.4 You can make other adjustments through the ports (1.51.9) in the housing
wall (1.51.1), which otherwise have to be kept closed.
If the need arises, POLYSIUS AG will issue special instructions for this purpose.
Fig. 39: Air distributor
en-PQ.CPT.001.B
®
Step 2: For dismounting the narrow air distributors (1.52), you have to release and
remove the folding connectors (1.52.5) at both ends.
2.1 When doing so, you must support the air distributor (weight max. approx. 5
kg).
2.1.1 You can then remove it in a downward or lateral direction.
In the case of the narrow air distributor (1.52) you can only exchange the
pendulum counterweight (1.52.2) when the unit has been dismounted.
2.2 To replace a pendulum counterweight (1.52.2), first remove one of the
spring cotters (1.52.8) and then pull out the pin (1.52.3).
2.2.1 You can then remove the pendulum counterweight.
2.3 Install analogously in reverse order to the dismounting.
Carry out the replacement analogously to the procedure described in the case of
the air distributor (1.51).
Fig. 40: Air distributor, narrow
en-PQ.CPT.001.B
®
Step 3: To replace the orifice plates (1.55, 1.56), you have to unscrew the
corresponding bolted connections (1.55.5, 1.56.5, 1.56.6).
The basis for the designation of the orifice plates is their orifice diameter.
Orifice plate (1.55) has one orifice, while orifice plate (1.56) has three orifices.
These orifice diameters are stated in the air distribution diagram.
Fig. 41: Orifice plate
After completion of all maintenance measures:
Make sure that all the inspection and maintenance openings are properly closed
again and are safeguarded against accidental opening.
Note
again in accordance with section Checks prior to the test run.
en-PQ.CPT.001.B
Machine manual Trouble shooting
®
9 Trouble shooting
DANGER
There is a risk of raw meal flushing into the clinker cooler.
I. Access to the cooler must not be possible as long as cleaning work is
being performed in the preheater.
II. The plant manager must take precautionary measures to ensure safety
of the maintenance personnel.
DANGER
When automatic air blast units are used after the electricity supply has
been switched off.
Danger of unintentional shooting, due to residual pressure.
Let the residual pressure escape before opening the doors and/or poke
holes.
DANGER
Clinker or parts of the refractory lining may fall down or give way in the
clinker cooler.
I. Make absolutely sure that there are no clinker incrustations or parts of
the refractory lining that could fall down in the cooler and in the kiln
hood.
II. Make absolutely sure that all clinker / parts of the refractory lining have
a sufficient load bearing capacity.
DANGER
There are hot gases inside the cooler.
There is mortal danger.
I. Make absolutely sure that there are no remaining hot gases in the
cooler and that no hot gases can enter the interior.
II. Wear the prescribed protective clothing.
III. Wait until the cooler has cooled down before starting the maintenance
work.
en-PQ.CPT.001.B
Trouble shooting Machine manual
®
WARNING
The machine is hot.
You could be seriously injured.
I. Wear the prescribed protective clothing.
II. Wait until the cooler has cooled down before starting the maintenance
work.
WARNING
There are rotating / moving components in / on the machine.
Do not enter the machine during operation of the machine.
WARNING
When inspection ports are opened, hot material may spatter out.
Wear the proper protective clothing and keep emergency escape routes
free.
WARNING
Open doors can move suddenly and without warning.
You might be crushed.
Secure open doors against unintentional closing.
WARNING
The noise level in the machine building can exceed 90 dB(A).
Your hearing could be harmed.
Wear hearing protectors.
Note
again in accordance with the section Preparation for test run.
en-PQ.CPT.001.B
®
9.1 Faults, causes and elimination of faults
Fault Cause Elimination
Material from the rotary If it is found during commissioning

kiln is not centrally that the material to be cooled is
discharged onto the not centrally discharged onto the
aeration floor aeration floor, you must correct
this by adjusting or replacing the
air distributors (1.51, 1.52) and/or
orifice plates (1.53, 1.54) or/and by
altering the Horse Shoe
dimensions.
RED RIVER When the material is In the majority of cases, the

discharged from the kiln, fine aforementioned problem can be
and coarse materials are prevented by adjusting the cooling
separated so that the cooling air distribution to the various
air cannot flow uniformly aeration zones on the clinker
through the material bed on cooler and by adjusting the stroke
the cooler grate due to lengths of the transport tracks in
differences in flow resistance. accordance with the clinker
This can lead to the situation discharge conditions of the rotary
that strips of the bed of cooling kiln.
material are only insufficiently Alterations of the operating mode
or not at all penetrated by the or the raw material may make it
cooling air. Such strips of necessary to modify the cooling air
material are called "RED distribution and adjust the stroke
RIVERS" and usually occur on lengths of the transport tracks.
one side at the edge of the
aeration floor. Normally, you can eliminate RED
RIVERS by increasing the air flow
rate in the affected zone. (Observe
the bed of cooling material!)
en-PQ.CPT.001.B
®
Sudden increase in Overloading of the clinker ● Change over the drive from
quantity of material to be cooler due to coating falling automatic to manual operation.
cooled down in the kiln. ● Reduce the kiln speed to a
degree ensuring that the
compartment air pressure in
the area of the measuring point
for the conveying speed
regulation is not significantly
higher than during normal
operation.
● Reduce the kiln feed rate
according to the extent of the
disturbance.
● Increase the cooling air flow
rate if necessary (increase in
exhaust air temperature).
● Monitor the clinker cooler
visually until the fault has been
eliminated.
Formation of snowmen in If the material to be cooled has ● Avoid fluctuations in the

inlet zone a tendency to stick together, chemical composition of the
there is a danger that it will raw meal and fuel.
build-up to form so-called ● Push the burner lance further
"snowmen". The tendency to into the kiln, so that a part of
stick together results from the kiln serves as pre-cooler
temporary overheating of the and the temperature of the
material often caused by high material discharged onto the
fluctuations in the chemical clinker cooler is reduced.
composition of the raw meal
and the fuel. ● Change the cooling air
distribution to the different
aeration units in the initial
cooler section.
● Improve the initial cooling
● If necessary, install additional
air blast units that are activated
at regular intervals and thus
prevent the formation of
snowmen.
en-PQ.CPT.001.B
®
Failure of the drive (14) See separate machine manual ● If the transport tracks of the first
aeration floor fail, the transport
tracks of the following aeration
floors can continue operating,
however only at minimum
stroke frequency to ensure that
the transport tracks will not run
empty. Immediately reduce the
speed of the rotary kiln to
minimum (auxiliary drive).
● To prevent damage, keep the
fans of the first aeration floor
running for at least 5 to 10
minutes with the current
setting. Throttle the fans of the
downstream aeration floors.
● If the transport tracks of
downstream aeration floors fail,
you must immediately empty all
upstream aeration floors in
accordance with the above
procedure. You must keep the
roll crusher (20.0) and the
conveyor for the cooler
discharge material running.
Failure of roll crusher See separate machine manual Switch off all the transport tracks.
Keep the aeration of the aeration
floors running for at least 5 to 10
minutes, in order to prevent
overheating. Immediately reduce
the speed of the rotary kiln to
minimum (auxiliary drive). Keep
the conveyor for the cooler
discharge material running.
en-PQ.CPT.001.B
®
Failure of single or all Faulty drive motors or broken Clinker coolers which are
cooling air fans V-belts interlocked in accordance with
POLYTRACK® standards are
switched off upon failure of one or
all cooling air fans. Keep the roll
crusher (20.0) and the conveyor
for the cooler discharge material
running. Reduce the kiln speed to
minimum. Make absolutely sure
that the clinker cooler is intensively
aerated. If the exhaust air fan of
the plant is still in operational
condition, increase the negative
pressure in the kiln hood and open
the doors under the aeration floor.
Replace any faulty parts as quickly
as possible.
Failure of the finished If this conveyor fails, you must

product outward immediately switch off all the
conveying equipment transport tracks; apart from this,
proceed as in the case of "Failure
of roll crusher (20.0)".
Note
Consult the subsuppliers' documentation for additional information on faults,
their causes and their elimination.
Note
again in accordance with section Checks prior to the test run.
en-PQ.CPT.001.B
Machine manual Spare parts
®
10 Spare parts
10.1 Suggestions for enquiries and orders of spare parts

Dear Customer,
POLYSIUS AG want to make spare part enquiries and spare part order
placement as easy and efficient as possible. For this purpose we have prepared
a table containing all data required by our spare parts department to ensure
optimum processing in the most speedy and trouble-free manner.
Please copy the title page and the page with the corresponding table. Complete
the columns for quantity and units. Mark the parts you require with a cross in the
column "Order" or in the column "Enquiry". Send the title page and the table to
the POLYSIUS AG spare parts department.
If the table relates to more than one machine, please also inform us of the
POLYSIUS Order Code (POC) of the machine for which you require the spare
parts.
For spare parts for the following subassemblies
● air blast unit (6.0)

● fans (21.0)
● refractory lining (22.0)
please refer to the subsuppliers' documentation.
For spare parts
● for the roll crusher (20.0)

please refer to the separate machine manuals.
Note
The spare parts for the grate equipment (1.0) are shown in the drawing
contained in section Technical drawings.
10.2 Spare parts
en-PQ.CPT.001.B
Spare parts Machine manual
®
Fig. 42: POLYTRACK® assembly
en-PQ.CPT.001.B
®
No. Name Qty. Unit Order Enquiry
4.10 Viewport, complete
4.10.1 Glass pane for viewport
4.10.2 Seals for viewports
en-PQ.CPT.001.B
®
Static pre-grate (1.20)
Fig. 43: Static pre-grate
en-PQ.CPT.001.B
®
1.21.1 Aeration unit (498x300)
1.21.2 Aeration unit (248x300)
1.21.3 Aeration unit with nozzle (498x300)
1.21.4 Aeration unit after nozzle (498x300)
1.21.5 Bolted connection of aeration unit
1.22.1 Internal part of aeration unit (498 x 300)
1.22.5 Connecting bolts of nozzle
1.23 Cover plate
1.29.1 Connections for air distributors (140 x 140 air

nozzle)
1.29.2 Connections for air distributors (54 x 150 sides

in the end grate zone)
1.29.5 Connecting bolts of the connecting sleeve

(1.29.1)
1.29.6 Connecting bolts of the connecting sleeve

(1.29.2)
en-PQ.CPT.001.B
®
Fig. 44: Grate equipment
en-PQ.CPT.001.B
®
1.1.1 Transport track
1.1.2 Transport track (start, end)
1.2 Aeration unit
1.2 Aeration unit, narrow
1.2.1 Aeration unit, internal part
1.2.1 Aeration unit, internal part, narrow
1.2.5 Bolted connection of aeration unit
1.3 Mounting plate for transport track
1.3 Mounting plate with sealing element
1.3.5 Bolted connection of mounting plate for transport

track
1.4 Pin of transport track
1.4.1 Disc of pin for transport track (only together with

pin 1.4)
1.4.2 Weld
1.5 Angle bracket for transport track
1.5.5 Bolted connection of angle bracket for transport

track
1.5.6 Fitting pin
1.6 Sealing frame, start
1.6.1 Thrust element
1.8 End cover
1.9 Intermediate piece
1.9.2 Sealant
1.9.5 Bolted connection, intermediate piece
en-PQ.CPT.001.B
®
1.10 Dam plate
en-PQ.CPT.001.B
®
Items shown in the drawing of the spring system (1.7)
en-PQ.CPT.001.B
®
1.7 Spring system, complete
1.7.1 Spring system, vertical
1.7.2 Spring system, horizontal
en-PQ.CPT.001.B
®
Items shown in the air distribution diagram (1.50)
en-PQ.CPT.001.B
®
1.50 Air distribution diagram, complete
1.51 Air distributor
1.51.2 Pendulum counterweight of air distributor
1.51.3 Pin for pendulum counterweight of air distributor
1.51.5 Bolted connection of air distributor
1.51.6 Folding connector
1.51.8 Spring cotter
1.52 Air distributor, narrow
1.52.1 Socket for air distributor, narrow
1.52.2 Pendulum counterweight of air distributor,

narrow
1.52.3 Pin for pendulum counterweight of air distributor,

narrow
1.52.5 Folding connector
1.52.8 Spring cotter
1.55 Orifice plate
1.55.5 Bolted connection of orifice plate
1.56 Orifice plate, narrow
1.56.5 Bolted connection of orifice plate, narrow
1.56.6 Bolted connection of orifice plate, narrow, loose

piece
en-PQ.CPT.001.B
®
Longitudinal girder (2.0) with bearing assembly
Fig. 47: Longitudinal girder with bearing assembly
en-PQ.CPT.001.B
®
Nut locking agent
Special cleaner
2.2 Slide rail
2.2.1 Slide rail, top
2.2.1.5 Bolted connection of slide rail, top
2.2.1.7 Self locking nuts, top
2.2.2 Slide rail, middle
2.2.2.5 Bolted connection of slide rail, middle
2.2.2.7 Self locking nuts, middle
2.2.3 Slide rail, bottom
2.2.3.5 Bolted connection of slide rail, bottom
2.2.3.7 Self locking nuts, bottom
2.3 Bearing block
2.3.1 Basic body
2.3.2 Slide plate holder
2.3.3 Bolted connection, slide plate holder
2.3.10 Bearing block, complete with slide plates
2.3.10.1 Bolted connection of bearing block, outer
2.3.10.2 Bolted connection of bearing block, inner
2.3.10.3 Self locking nut for bolted connection of

bearing block, outer
2.3.10.4 Self locking nut for bolted connection of

bearing block, inner
2.4 Slide plate
2.4.5 Bolted connection, slide plate
2.5 Fishplates for longitudinal girder
2.6 Bolts, longitudinal girder
2.6.1 Disc of pin for longitudinal girder
2.6.5 Bolted connection, longitud. girder fishplates
en-PQ.CPT.001.B
®
2.6.5.1 Locking plate for bolted connection of

longitudinal girder fishplates
en-PQ.CPT.001.B
®
Items shown in the drawing of the doors and inspection ports (9.0)
Fig. 48: Doors and inspection ports
en-PQ.CPT.001.B
®
9.10 Inspection port, complete
9.10.1 Glass pane for inspection port
9.10.2 Seal for glass pane of inspection port
en-PQ.CPT.001.B
®
Items shown in the drawing of the lighting unit (9.20)
Fig. 49: Lighting unit
en-PQ.CPT.001.B
®
9.20 Lighting unit
9.20.4 Lamp
9.20.5 Glass
9.20.6 Protective basket
en-PQ.CPT.001.B
®
Thermocouple (10.1)
en-PQ.CPT.001.B
®
10.1 Thermocouple
Note
For detailed spare parts lists, please refer to the subsuppliers' documentation.
en-PQ.CPT.001.B
Machine manual Appendix
®
11 Appendix
11.1 Technical drawings

Note
For drawing numbers, please refer to the table of contents of this folder.
Assembly drawing
11.2 Subsuppliers' documentation
Fans
Air blast unit
en-PQ.CPT.001.B

POLYTRACK® Clinker Cooler With Intermediate Crusher

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

POLYTRACK® Clinker Cooler With Intermediate Crusher

Transféré par

Droits d'auteur :

Formats disponibles

Machine manual

POLYTRACK® clinker cooler with intermediate crusher

POLYSIUS Order Code (POC)

8.4.15Replacing the thermocouples for temperature measurement on the

● The machine is exclusively intended for burning small-sized or granulated

● Make absolutely sure that the hydraulic piping is depressurised before it is

Specification of the intended use

Number of transport tracks

Number of modules over cooler length

Number of modules over cooler width

Width of the aeration floor mm

Length of the aeration floor mm

Area of the aeration floor m2

Area of the aeration floor (actively m2

Number of aeration floors

Inclination of the cooler and of the °

Offset between longitudinal cooler mm

Offset of longitudinal cooler axis left/right

Temperature monitoring system for the transport tracks

Air blast unit

Aeration of the POLYTRACK® clinker cooler

Fan no. Compartment no. Volume flow Static pressure

3 Components and mode of functioning

Fig. 1: POLYTRACK® assembly

No. Name Description

1.0 Grate equipment

2.0 Longitudinal girder with bearing assembly

3.0 Grate substructure

3.1 Cross girder

4.0 Lower housing section

4.10 Viewport divided

4.20 Partition upper

4.30 Partition lower

4.11 Sealing flap

5.0 Upper housing section

5.1 Exhaust air duct socket

6.0 Air blast unit

9.0 Doors and inspection ports

20.0 Roll crusher

21.0 Fans are not shown in the figure

22.0 Refractory lining

Static pre-grate (1.20)

Fig. 2: Static pre-grate

No. Name Description

1.20 Static pre-grate initial zone of the static grate

1.21 Aeration unit

1.22 Aeration unit in front of

1.23 Cover plate

1.24 Nozzle for air blast unit

1.27 Protective plate

1.28 Connecting sleeve for nozzle

1.29 Connections for air distributors

1.30 HORSE SHOE

Grate equipment (1.0)

Fig. 3: Grate equipment

No. Name Description

1.0 Grate equipment including static pre-grate

1.1 Conveying element Transport track

1.2 Aeration unit Aeration floor

1.3 Mounting plate for transport track

1.4 Pin for transport track

1.5 Angle bracket

1.6 Sealing frame