A4-P 4.0 en

FLSmidth Cross-Bar Cooler
Hydraulic equipment for movement of drives
Operation and maintenance instructions
Created by: CJOE

Approved by: VRGO
FLSmidth, 05-Sep-12 70018190-4.0
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Foreword
The present instructions are concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur during manufacture, installa-
tion, operation and maintenance of the equipment. An exhaustive enumeration of
all conceivable situations, which may occur, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in
the instructions, and which the operator is/or feels unable to handle, it is recom-
mended that FLSmidth is contacted without undue delay for advice on appropriate
action.
All references to relevant safety standards are given at the EC declaration of con-
formity if required.
Reference by seller to any international or national standard does not incur an
obligation on seller to provide any recipient, reader or user of the documentation
with samples or copies of the said standard(s).
Hence, any recipient, reader or user of the documentation is expected at his own
cost to obtain necessary knowledge of the contents of any of the standards
referred to.
Safety
Potential safety risks, and correct mode of conduct subject to such risks, are con-
tinuously described in the text in relation to specific actions.
See instructions 32031 for general safety rules and the separate equipment-specific
safety instructions for a complete list of all unforeseen risks in connection with the
installation, operation and maintenance of the equipment.
Definitions and abbreviations

Authorized person A person who is qualified and who, by the responsible manag-
er, is entrusted with certain tasks.
Skilled person A person who, after an education as a craftsman, is capable of
doing skilled work.
SDS Safety Data Sheet (in US known as MSDS)
MSDS Material Safety Data Sheet
OM Operation and Maintenance
Legend
Warning
This symbol indicates dangers which, in case of non-observance, may cause fatal or
serious personal injuries!
Warning text is concluded with a filled black triangle to symbolize end of warning
text.
Attention
This symbol indicates important information where specific attention and caution is
needed. For example to avoid damage to or destruction of the equipment and/or
parts of the installation.
Attention text is concluded with a filled black square to symbolize end of attention
text.
The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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Table of contents
1.0 Safety .................................................................................................... 5
1.1 Personal protective equipment ............................................................. 6
2.0 General Information ................................................................................. 7
3.0 Construction and operating principle........................................................... 8
3.1 Hydraulic pumps ................................................................................ 8
3.2 Oil conditioning - booster/servo pump and bleed-off valve ....................... 9
3.3 Servo oil ...........................................................................................10
3.4 Alarms and interlocks .........................................................................11
4.0 Installation .............................................................................................13
5.0 Operation ...............................................................................................14
5.1 Initial start-up procedure ....................................................................14
5.1.1 Hydraulic oil .............................................................................14
5.1.2 Flushing of pipe system..............................................................15
5.1.3 Initial starting to be effected from the local control panel. ..............18
5.1.4 Start-up ...................................................................................18
5.2 Normal remote-operated starting from centralized control panel ..............21
5.2.1 Preconditions for remote-controlled starting .................................21
5.3 Controlling of drives - starting position for operation ..............................21
5.3.1 Operational description ..............................................................22
5.4 Pump switching .................................................................................24
5.5 Cooling.............................................................................................24
5.6 Oil heating without starting the hydraulic piston movement ....................24
5.7 Manual operation ...............................................................................24
6.0 Maintenance see suppliers manual..........................................................25
7.0 Remedial action see suppliers manual. ....................................................25
8.0 Appendices.............................................................................................25
Appendix 1 Main pump with switch-over-block ............................................25
Appendix 2 Stand-by pump with flushing filter ............................................27
Appendix 3 Tank and conditioning circuit ...................................................29
Appendix 4 Cylinders with bleed-off valves .................................................31
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1.0 Safety
Always follow instruction 19871 Installation, operational preparations and mainte-

nance and the equipment specific hydraulic instructions from FLSmidth and from
hydraulic supplier.
Warning
Hydraulic oil may cause eye, skin or respiratory irritation. High-pressure
injection under skin may cause serious damage.
When hydraulic oil is filled or refilled to the hydraulic tank, Safety Data
Sheets for the oil must be obtained and the safety procedure must be
followed when working with hydraulic oil.
Warning
Pressurized oil leaks can be extremely dangerous and cause serious
person injury or even death if injected under skin.
To minimize risks of pressure leaks, all hydraulic connections must be
securely fastened. During pressure test, all personnel must keep a safe
distance to all hydraulic equipment and wear visor.
Never use hands to locate a leak.
Leaking joint may ONLY be tightened when the hydraulic system is
completely depressurized.
Warning
If hydraulic hoses connecting to e.g. the hydraulic cylinders are leaking,
the risk of fire is available.
Hydraulic oil flow must be stopped immediately and the ball valves
nearest must be shut off before replacing or tightening the leaking part.
Warning
In the hydraulic room the risk of fire and explosion is available.
Always keep the hydraulic room and hydraulic power unit clean and free
from spillage oil.
The pressure accumulators to be precharged ONLY with dry nitrogen (N2)
Smoking is prohibited.
Warning
Risk of injury from hydraulic components e.g. uncontrolled hoses being
disassembled with pressurized oil inside.
Disassembling hydraulic connections must only occur when hydraulic
system is completely depressurized.
As a further safety precaution, only loosen the union on hydraulic connec-
tions e.g. connection between hose and hydraulic motor one turn before
loosening the hose from the connection. When this is done and it has
been confirmed that no pressurized oil is inside, the union can be com-
pletely loosened.
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1.1 Personal protective equipment
Ear protectors have to be used when noise level (sound pressure) is above 85 dBA
Safety helmet, protective glasses and safety shoes are standard protective equip-
ment to be used
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2.0 General Information
The drives of the cooler are moved backward and forward by means of the electro-
hydraulic equipment.
Figure 1 - Hydraulic Pump Station
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3.0 Construction and operating principle
See Appendix 1Appendix 2Appendix 3Appendix 4
3.1 Hydraulic pumps

The equipment consists of hydraulic cylinders and pump units, connected to a
common oil tank. The pump station has a local control panel featuring a program-
mable logic controller.
It is equipped with stand-by unit, which allow production, even though one main
pump is out of function.
Each pump unit consists of a main pump (310) - Appendix 1- with a built-on pro-
portional valve and a combined servo- and boost pump on the same shaft. During
operation, only one pump unit is running for each drive, whereas the last unit
serves as a backup unit for the normal pumps in active operation.
All pumps are identical, being operated at a speed depending on the frequency 50
or 60 HZ.
The main pump is an electrically-operated axial piston pump featuring variable
output and reversibility of pump direction. The output of the pump and the direction
in which the pump is operated are determined by the position of a "rocker cam,
the setting - angling - of which will determine the oil flow rate of the pump and
whether the pump is to be utilized for port A or B.
The hydraulic system is based on a closed circuit principal. When the pump is
angling to the one side, oil will move the cylinders in one direction. At the same
time, oil from the opposite cylinder port, is directed back to the pump. When the
pump is angling to the other side, the situation is just opposite and the cylinders
are moved in the other direction.
To ensure that the oil is replaced at the cylinders, bleed-off valves are installed just
after the last cylinder in each line. The valve lets approximately 20% of the oil flow
back to tank.
The output of the main pumps is controlled by the PLC controller, via the propor-
tional valves of the pumps.
The tank is equipped with a hand pump (190) which can be connected to the pipe
sections towards the cylinders so that the latter can be moved manually when the
pump station is inoperative, for example in connection with maintenance work
involving the movable frames of the cooler.
The stand-by pump is switch in electrically from the Local Control Panel (LCP). This
is done through the switch-over-block (500).
Ball valves (505) are for maintenance only and are equipped with brackets for
padlock.
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Linear transducers are fitted on each of the movable drives. They continuously
provide the PLC unit with specific position of the drives.
Based upon the positional indications of the cylinders, the PLC unit releases a signal
to the main pumps when a reversal in the direction of pumping, and thus the
directional movement of the piston, is to be made.
All the drives are identical, but must be operated independently of one another. A
drive is driven by cylinders connected in a row. One of the position transducers
continuously feeds a signal to the PLC unit to determine the exact timing for the
reversal of movement. The second transducer is used as a back-up unit and for
alarm tripping if there is no movement of the drive.
The total stroke length of the cylinders is 340 mm, of which only 300 mm is nor-
mally required by the drive, thus leaving 20 mm at either end as an oil cushion and
as a reserve for conveyance. Therefore, shock impacts in the system resulting from
the piston striking against the ends of the cylinder will not occur.
When the transducer indicates that, for example, 15 mm of the movement of 300
mm remains to be completed, the PLC unit will begin, via the proportional control
valve, to slow down the cylinder; the output of the pump will bring the drive to a
standstill, by the rocker cam being turned to neutral position while completing the
remaining 15 mm.
However, the "rocker cam" of the pump does not stop at the zero-point, but contin-
ues in the same direction until its position is reversed, causing oil to be pumped in
the opposite direction.
This will lead to a change in the direction of movement of the cylinders, causing
them to accelerate to the same velocity in the opposite direction.
The cylinders are installed with every second, pushing in the opposite direction,
ensuring an identical velocity of the conveying and return stroke of the drive.
The forces required to push the clinker forward and to pull the drive backward
through the clinker layer are not of equal strength. Therefore, there will be a slight
difference in the pressure in the two directions.
3.2 Oil conditioning - booster/servo pump and bleed-off valve

As previously noted, the main pumps and cylinders operate in closed circuits, and
this means that it is basically the same oil which is being circulated in the individual
circuits.
The two pipelines carrying the oil for all the cylinders of a drive are equipped after
the last cylinder - with a bleed-off valve (flushing valve) (0050). See Appendix 4
This is to prevent the same oil from being circulated from the pump to the cylin-
ders.
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The bleed-off valve is governed by the differential pressure between the input flow
and the return flow in the main circuit.
When the differential pressure of the movement exceeds a level of 16 bar, the
bleed-off valve opens and directs oil to the tank through the primary water oil
cooler (140) and the double return line filter (150), see Appendix 3
The pressure on the low-pressure side is then determined by the booster pump and
the pressure loss in the pipelines.
From the tank, fresh oil is constantly fed to the circuits via the internal booster
pump in the main pump (310).
The booster pump ensures that a sufficient oil volume is constantly maintained on
the suction side of the main pump. To further ensure that this is the case, a hy-
draulic accumulator (460) is incorporated between the booster pump and main
pump to ensure that the necessary quantity of oil is present in case of rapid flow
variations.
The additional booster oil for the main pumps is ensured by an internal pressure
relief valve set at 35 bar.
To maintain required quality of the oil, the oil is continuously circulated with the
pump (225) and are cleaned and cooled via the circulation filter (155) and the
secondary water oil cooler (240).
At the same time, the pump supplies the main pump housing with warm filtered oil,
which extent lifetime for the bearings.
Furthermore the pump is used to fill up the reservoir with suction hose (4210) and
to empty it with drain hose (4237). See Appendix 3
The condition circuit is running continuously when the main pumps are running. At
least 24 hours prior to a main pump start-up, the conditioning circuit must be
started.
At any kiln shut down of short duration, the conditioning circuit should remain in
operation to maintain the oil temperature.
At least 24 hours prior to a main pump start-up, the conditioning circuit must be
started.
At any start-up and production situation, the hydraulic equipment and room is
designed for minimum 0C. The circulation pump can be started at any tempera-
ture beyond this level.
3.3 Servo oil

The proportional control valve receives servo oil from the combined servo- and
boost oil pump of the main pump at a pressure of 35 bar preset on an internal
valve built into the pump. Readings of this servo pressure can be obtained on
pressure gauge (471). The proportional control valve governs the rocker cam of
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the main pump; the position of the rocker cam will determine the pump output as
well as the direction of oil flow to A or B.
The preset pressure of the oil for the proportional control valve must ensure that
the operating speed of the valve is sufficient. Surplus servo oil is directed to the
booster system.
Attention
If any parts of the servo- or booster oil circuit require dismantling, it will
be necessary to relieve the accumulator pressure prior to dismantling.
Normally, the pressure will be eliminated quickly through the accumulator
safety block, and the pressure (0 bar) can be read on pressure gauge
(471).
A final manual releasing for safety reason is recommended. Round handle
on accumulator safety block (465) must be open for releasing the pres-
sure in maintenance situations
3.4 Alarms and interlocks

See Appendix 1Appendix 2Appendix 3and instruction manual for electrical equip-
ment.
Level switch (125) will trip first a warning alarm and later it will stop the electric
motors if the oil level is too low. The oil level can be visually inspected through oil
level glass (120)
The temperature transmitter (130) features built-in temperature monitoring.

The temperature transmitter will prevent the motors from being started if the oil
temperature is too low and it will trip first a warning alarm and later stop the pump
station if the oil temperature is too high.
For oil VG 46 a prewarning will set the alarm at 55C and stop the pump unit at
60C
During normal condition, the water valves (142) and (242) will regulate the water
depending of the temperature.
The booster pressure is monitored from the pressure transmitters (318). The main
pump stops in case of a pressure drop to level below 15 bar.
The booster pressure can be observed on pressure gauge (471).
The ball valves (305) ahead of the pumps are equipped with switches for interlock-
ing the pump motors.
All filters are equipped with differential pressure controllers for tripping of alarm in
case of clogged filters.
At the bottom of the tank there is a drain valve for collecting condensation, if any.
When the plant is in normal operation, the oil temperature will be high enough to
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prevent condensation, but collection of condensation in the tank may occur during
the periods when the plant is at standstill.
If Water detector is an option on the specific pump station, there will be two
alarms. The first alarm is a prewarning if the water content exceeds the prewarning
level. The second one is a full stop.
If particle counter is an option on the specific pump station, there will be two
alarms. The first alarm is a prewarning if the oil cleanliness exceeds the prewarning
level. The second one is a full stop.
The block for stand-by unit, for changing between main pump and stand-by pump,
is electrically controlled. This means that a change from main pump to stand-by
pump is done only by using the Local Control Panel (LCP).
Ball valves are located between pumps and cylinders for shutting off. The valves
have no micro switches for monitoring the position. They are only for safety reason,
when isolation on a specific pump prior to maintenance is required.
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4.0 Installation
Installation to be carried out in accordance with drawings and pipe diagrams and
otherwise as directed in the instruction manual 19871, HYDRAULIC PLANTS, and
suppliers manual.
However, we normally recommend that pipe bends is used whereas the use of
angles must be avoided.
The pump station is normally shipped in a container and it must not be removed
from the container until installation of unit at site is imminent. If the pump station
is shipped in the unpacked condition (which is sometimes the case for certain
destinations), the unit must be kept in a dry place and must be protected against
dust in a store room up to the point of installation. This also applies for the electri-
cal cabinet and pipes and loose fittings.
The hydraulic pump and motor number 1 (nearest the tank on the pump station)
must be connected to the cylinders on the left-hand side of the cooler (viewed in
direction towards the cooler outlet).
For port connection, please follow diagram carefully in vendor instruction.
(One pump drives one driveline).
Place screwed connections for aeration in the pipes situated at the highest loca-
tions.
Do not remove the plugs in the cylinders and do not connect them to the pipe
system until the system has been flushed and is ready to be pressure tested.
Otherwise there is a risk of contaminating the cylinders.
Keep all plugs for future maintenance!
Attention
The hydraulic pump and motor number 1 (nearest the tank on the pump
station) must be connected to the cylinders on the left-hand side of the
cooler.
Avoid use of angles, if possible.
Absolutely cleanliness during any work with hydraulic equipment, is of the

utmost importance for a full functional system
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5.0 Operation
5.1 Initial start-up procedure
5.1.1 Hydraulic oil

The additives in the hydraulic oil may cause skin problems, and severe eye prob-
lems. The precautionary measures indicated on the data sheets from the oil suppli-
er must be observed.
Oil quality: FLS Mat. No. 7025. Corresponding to ISO VG 46.
At sites with very high or low ambient temperature, ISO VG 46 can be replaced
with ISO VG 68 or ISO VG 32, with benefit for the system.
Oil grade VG 46 is recommended for operation with the oil temperature maintained
within the range 55-60 C. If a lighter or heavier type of oil is deemed to be more
appropriate, the oil temperature must be adapted to the new oil type. See data for
pump in suppliers manual. Data and settings in suppliers manual always overrule
data or settings in this manual.
Oil filling must only be done using the pump (225) as follows:
a) Check that hose and quick release connections are clean. The hose is located
at the pump station.
b) Establish a hose connection between the suction side of pump (225) and the
oil drum.
c) Place the free end of the hose in the barrel containing the fresh oil.
d) Close all suction valves on the tank and supporting structure. Place a bucket
under the drain valve at the bottom of the tank and open it, for draining any
accumulated water.
e) Close all valves (313) leading into the main pumps, preventing air from
entering the main pumps.
f) Make sure that 3-way ball valve (210) is shutting of suction line from the
tank.
g) Jog-start pump (225) in order to check the direction of rotation.
h) Start the filling operation and stop the pump when suction is done from an
empty barrel; the sounds emitted will clearly indicate whether the barrel is
empty.
i) Fill the tank to the upper mark on the oil level glass (120).
Stop the pump (225) and disconnect the filling hose.
j) Position the 3-way ball valve (210) so that pump is being supplied with oil
from the tank.
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Attentions is drawn to the fact that fresh oil is NOT clean, and therefore,
the pump (225) must be started and remain in operation for some time,
since this will cause the oil to be returned through the filters and cleaned
prior to any transmission of the oil to the cylinders. Filtration of the oil also
takes place by circulating it through the main pumps, but use of the filter
(165) should be avoided at this point so valves (311) are to remain closed
until the pump (200) and the filters (150) have removed impurities from
the new oil.
See details in subsequent section.
5.1.2 Flushing of pipe system

(See instruction manual 19871 for initial preparation of hydraulic plants and suppli-
ers manual).
The service life and reliability of hydraulic systems depend entirely on the cleanli-
ness of the system.
It is of the utmost importance to ensure absolute cleanliness of the oil. It is

essential to avoid impurities of any kind in the pipelines and in any of the compo-
nents. Therefore, the system must be flushed out before it is connected to the
pump station and the hydraulic cylinders.
Normally, this level of cleanliness can only be achieved by using a special filter
pump equipped with the necessary equipment for ensuring rapid pressure and flow
variations in order to dislodge impurities and rust in the pipe system (flushing
system). This flushing procedure is strongly recommended by FLS.
Fresh oil does not have the necessary degree of cleanliness, and, therefore, the oil
must be cleaned after being charged to the system.
The circulation pump (225) is used to clean the oil in the tank and the equipment
on the pump station by diverting the oil through the filter (155). Meanwhile the oil
is heated with the heating element to the highest possible level (preferable 60C).
The pump must be maintained in operation until the system has been effectively
cleaned. Minimum 24 hours for the filtration sequence.
Requirements in terms of cleanliness: ISO 4406, class 18/16/13.
When the filtration process is completed and all pipes are cleaned manually with
clean rags and dry compressed air, then the flushing can begin. Start with cold oil
app. 20C and let it during the flushing process heat up to the highest possible
temperature (preferably 60 C)
If the pump station is with Particle counter as option, the flushing can be carried
out with the standby pump. In this case, the flushing can be stopped when level of
cleanliness is two codes below system requirements.
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If the pump station is without Particle as option, FLS recommend flushing with an
external flushing unit for at least 24 hours or until oil samples is acceptable two
codes below system requirements.
Please see guidance in suppliers manual, besides text below.
Attention
The plugs in the cylinders must remain fitted until flushing of the pipelines
has been carried out.
Attention
The pump will sustain severe damage if contaminated oil is re-circulated
to the pump, or if they are not filled prior to start-up. Use only clean
filtered oil.
The next step involves selection of the drive and pipe system which are to be
flushed first.
The ball valves (7240) on Appendix 4 must be connected to the two hoses (7251),
which in term will be connected to the cylinders at the subsequent operational
stage of the plant. The hoses (7212) near the shuttle valve must be connected to
the ball valve (7215) so that all oil is forced back to the pump, in order to prevent
contaminated oil from reaching the shuttle valve (0050). In the beginning all ball
valves (7240) must be closed, and the valve (7215) must be open. Please refer to
Appendix 4
To determine whether the angling of the standby pump is correct, the pump must
first be jog-started with closed ball valves (7107) and the rotational direction of the
motor must be checked.
If noise is emitted by the pumps at subsequent stage when they become operation-
al, a check is needed to determine that they are filled with oil, accompanied by a
cautious relaxation of the drain ports until outflow of oil is observed.
The ball valves (7107) must be kept closed, and subsequently the pump is started
without angling, with the pump being cautiously angled until it has been definitely
established at which side of the pump angling is to take place. This can be deter-
mined by touching the hoses, or by checking the pressure gauge (510) when the
pump delivers oil to port B. This must be done with a low maximum pressure which
is adjusted on the local control panel.
The pump can then be started without angling, with subsequent opening of the ball
valves (7107) in direction from the standby pump to the pipe section which is to be
flushed, thereby initiating the flushing procedure. The rate of angling of the pump is
slowly increased towards the maximum limit while the oil pressure and filter are
closely monitored. After the oil has been cleaned, the ball valves (7240) at the
cylinders must be opened one by one, starting with the cylinder in immediate
proximity of the shuttle valve. When the first valve (7240) has been opened the
valve (7215) at the shuttle valve must be closed. Only one ball valve (7240) is to
be open at any one time however, see information subsequently provided in this
section. After the oil has been cleaned, the ball valve (1150) is cautiously opened at
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the next cylinder from the shuttle valve, and (7240) nearest the shuttle valve is
cautiously closed. The procedure is repeated for the hoses for all the cylinders in a
row, with only one hose opened at any one time and in the exact sequence from
the shuttle valve.
Now the pipes must be pressure tested. Open all valves (7240) and (7215) at the
shuttle valve (0050), close the valve (7107) in the A line only.
Only close valve in A-line, when pressure testing. All pipes will then have
pressure except the line from valve (7107) to the flushing filter at the
pump station.
Pressure test the lines up to 250 bar and the pump must be angled to same
side as when flushing, port B (VERY IMPOTRTANT). Otherwise only the
hose from the A port will be pressure tested.
Attention
Throughout pressure testing, one person must be ready at the emergency
stop so the pump can be stopped immediately in case of severe leakage
from a pipe joint.
Warning
Wear protective glasses and keep unauthorized personnel away from the
pipes. When pressure testing is being conducted, the operating personnel
must be a safe distance away from the pipe system to eliminate the risk of
injuries to skin and/or eyes.
The remaining part of the pipe system will be pressure tested later.
Having achieved effective cleaning of the pipes and oil, the pump is stopped and
the ball valves (7107), (7215) and (7240) are closed to minimize spillage of oil
when the coupling of the two hoses at the shuttle valve is dismantled and the hoses
are connected to the shuttle valve. See Appendix 4
Subsequently, the pump is re-started without angling, (remember to adjust the

pressure down form the 250 bar used for pressure testing) and the ball valves
(7107) and (7205) are opened along with the ball valve (7240) nearest the shuttle
valve.
Subsequently the pump is slowly angled in the same sideways direction as before,
until the maximum rate of angling has been achieved. After the pipes have been
cleaned, the ball valve (7240) is cautiously closed until the pressure drop across
the ball valve is sufficient to ensure activation of the shuttle valve and simultaneous
flushing of its pipeline. This can be detected by feeling the temperature rising in the
drain pipe.
The procedure must be repeated for the other pipe systems.

Prior to shipment, the local control panel has been set for a pressure of approxi-
mately 50 bar, and this pressure may have to be increased during the flushing
procedure when the entire oil flow is to pass across one ball valve (7240). At a
pressure drop above 50 bar, two ball valves must be kept open simultaneously. At
a pressure drop above 100 bar, the oil is heated and the motor is severely strained;
as a consequence hereof, high pressure drops should be of short duration. For this
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reason, the pressure compensation set point of the pump must be approximately
120 bar during the entire flushing procedure.
This limitation of pressure is of even more importance in order to protect
the filter cartridge against rupture in the event of a sudden blockage,
entailing risk of severe damage to the pump!
During the flushing process, the pressure drop across the flushing filter must be
strictly monitored and the filter cartridge must be replaced immediately in case of
any signs of obstruction.
During the flushing process, the oil temperature must always be maintained within
the range 55-60 C to ensure at the same time a low viscosity of the oil for optimiz-
ing the cleaning process.
The return filters (150) must be continuously monitored and a replacement of the
filters will be necessary if an alarm indicating obstruction of the filters is tripped.
Maximum cleaning efficiency is achieved if the high oil temperature is maintained,

accompanied by simultaneous maximum supply of oil from the pump. The latter
condition is necessary to generate effective flow of the oil in the pipes, ensuring
entrainment of particles. During flushing operations, the oil pressure must be
monitored on the pressure gauges and the temperatures by feeling on the pipes.
After flushing of all drives, the hoses from the stand-by pump must be disconnect-
ed from the check valves and attached to the foreseen joints with metal blind plugs
in. The blind plugs are to be used for the check valves. Please observe strict disci-
pline to avoid contaminating the now clean system.
The pipe systems have now been cleaned and the hoses can be connected to the
cylinders; always ensure that these connections have been cleaned prior to assem-
bly. The ball valves (7107) must be closed.
The remaining pressure test of A-lines from the pump station to ball valves (7107)
can be done now. They too should be pressure tested to 250 bar.
If it becomes necessary to start up the main pumps before the drives can be put
into operation, this must be done with the ball valves (7107) closed and without
any angling of the pumps.
5.1.3 Initial starting to be effected from the local control panel.

Pump units and the entire pump station have been tested prior to shipment to site.
The electrical control panel has also been tested.
5.1.4 Start-up
a) Check that all suction valves (305) are open.
b) The cylinders must not be connected to the drive at this point, but the cylin-
ders must be supported to allow them to move freely.
Alternatively, the movement of the drive has already been checked by means
of jacks or a hoist, which means that it will be perfectly safe to connect the
cylinders.
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c) Set the pressure limiter at 50 bar on the control cabinet.
d) Start the pump motors momentarily and check the direction of rotation. This
must be done in consultation with the supervisor of the electrical installation
and the rocker cam must be in 0-position, meaning no flow to cylinders.
Attention
Prior to operating the drives with the pump units, the movement of
the frame must be checked.
If the system is flushed and the cylinders are connected, the hand pump (190)
may advantageously be used to perform the checking. Cleaning must be
carried out before the connections are established.
It must be possible to move the drives at a low pressure (30 bar).
The recommended approach involves connecting the hand pump to the quick-
action coupling (194).
Attention
It is essential to prevent contaminated oil from reaching the cylin-
ders. Therefore, the oil in the tank must be cleaned before the hand
pump is used.
The movement can also be checked while the pump station is in operation,
with the pressure relief valves set for a pressure of approximately 50 bar and
with application of a very small oil volume.
Start the pump and operate it at 10-20% of the rated capacity - do not exceed
this limit. This is done using the PLC control unit. The output capacity of the
pump is adjusted on the electrical control panel.
e) Check that the pressure of the servo-/booster pump is 35 bar when the tem-
perature of the oil is normal ~ 60C. The oil pressure can be observed on
pressure gauge (471).
f) Let the cylinders move back and forth very slowly between the preset extreme
positions. Venting must be done while the cylinder is working, using the
supplied hoses and screwed connections with T-pieces for the hoses or by
relaxing the screwed connections situated at the highest locations until all air
has been expelled from the system. This operation must be repeated until the
air content in the oil is zero.
Some degree of venting is expected to take place through the shuttle valve.
Without any material in the cooler, quite small oil pressures are necessary to
move the drive, and therefore, the shuttle valve may not work exactly as
intended with replacement of the return oil from the cylinders. This can be
ascertained by touching the pipe connections relative to the cylinders and the
drain line from the shuttle valve, and it can be monitored via the flow switches
(0055).
Adjust the linear transducers in the two end positions, see instruction manual
for electrical equipment.
Then adjust the position of the transducer in relation to the cylinders.
g) Maintain the hydraulic system in operation for two hours, while slowly increas-
ing the operating speed.
70018190-4.0
Page 20 of 32
Set the thermostatic set points of the cooling circuit for attainment of an oil
temperature of approx. 60C.
h) Check that the speed (spm) is correct.
i) Measure the true length of the piston stroke and compare it to the set point
values. Set the length of the normal stroke as indicated below. Then check
that the resulting stroke length will be 300 mm. This adjustment is done by
cautiously altering the FS and RS values as well as the braking and accelera-
tion cycles. Be very careful when altering any braking cycles which will have
an impact on the braking length.
There must be an oil cushion at both ends.
This must be checked at several speed levels, also at the
maximum speed. See sub-section 5.3.1.
20 mm REVERSE STOP
320 mm FORWARD STOP
The stroke length can be increased at subsequent point in time if enhanced

conveying capacity of the cooler is required.
Since the rocker cam of the pump has a hysteresis, the program itself will
make an adjustment of the forward auto stop and the reverse auto stop in
accordance with the measured movements.
It will probably be necessary to revise these settings - particularly the acceler-
ation cycles - when corresponding data have been recorded during normal
operation. Data must be recorded at a normal oil temperature, approximately
60C.
j) When pressure testing is being conducted, the operating personnel must be a
safe distance away from the pipe system to eliminate the risk of injuries to
skin and/or eyes.
k) The 0 position of the pumps (0 angling), i.e. the position of the rocker cam
inside the pump, must be checked.
Check the adjustments on the pump card. See instructions from the electrical
department.
The adjustment, in its entirety, can be checked, if necessary, by adjusting the
flow in both directions via the pump card, duly recording at this location the
exact time for the occurrence of pressure and movement in the two directions.
l) Start up slowly by operating the pumps and the drives at minimum speed,
often 3-4 spm, for one hour while strictly monitoring the service pressures and
the general state of the cooler. See also instruction manual outlining the
guidelines for erection. Subsequently, the speed can, gradually within a period
of one hour, be increased to a level close to 20 spm, and this level must be
maintained for more than 6 hours. Check that drive plates or U profiles are not
getting hot from the friction with the C profiles, this can be felt or seen from
the under grate chamber, correct if necessary. See erection instruction.
Note: this check must only be done when the cooler is stopped. The stroke
lengths and oil temperatures must be checked at least 3 times. If necessary,
adjust the temperature setting for activation and de-activation of oil cooler.
Following a stoppage, the oil filters should be checked, and should normally be
70018190-4.0
Page 21 of 32
replaced, unless this has already been done after the flushing operation. From
the shuttle valve, about 2 liters of oil must be extracted, since, most often, the
pressure differential will be insufficient for the shuttle valve to be activated in
no-load condition, i.e. there is no replacement of oil.
m Repeat the venting operation as described in item f.

)
5.2 Normal remote-operated starting from centralized control panel
5.2.1 Preconditions for remote-controlled starting

The preconditions for starting the drive from a centralized control
panel are as follows:
a) Always ensure that interlocking alarms resulting from the monitoring of tem-
peratures, oil levels, etc. do not occur.
b) All valve handles must be placed in open position.
c) The electrical control panel must be switched to operation from the control
centre.
Once compliance with these preconditions has been ensured, the hydraulic plant
will be ready for remote-controlled start-up.
5.3 Controlling of drives - starting position for operation

See description in the instruction manual for electrical equipment.
The hydraulic pump is started in no-load condition (0-angling), its angling being
subsequently altered so that the piston of the cylinder is forced against that end of
the cylinder which is furthest away from the starting point.
70018190-4.0
Page 22 of 32
5.3.1 Operational description

See description in instruction manual for electrical equipment.
Movement of the drive is maintained within a range of 300 mm using the following
braking points:
I_____I_____I____________________I____I______I_____
0 RS RAS FAS FS 340
RS Reverse Stop
RAS Reverse Auto Stop
FAS Forward Auto Stop
FS Forward Stop
From the starting position, movement is started at the velocity requested by the
central control panel or the local control unit.
In connection with the adjustment of transducers and checking of movements, it

may be necessary for the operators assigned to such tasks to enter the cooler. This
involves a risk of the person sustaining injuries if squeezed/crushed by moving
parts. Therefore, any such operation must be strictly monitored by the plant
supervisors and a heightened state of alertness must be ensured so that the
installation can be shut down immediately in case of an emergency.
The pistons of the cylinders move forward at the preset velocity until they reach the
point FAS. The angling of the pump is then adjusted to 0 within the duration of the
braking length to the point FS.
After the "rocker cam " has reached 0-position (0 pump angle), the oil flow is
diverted to port B by moving the "rocker cam " to the opposite side. This is done
within the time period allowed for "Reverse Up Ramp".
70018190-4.0
Page 23 of 32
Oil flow from port A

STOP AUTO FORWARD
forward
is reached
Ramping
Ramping down
up reverse reverse
STOP reverse
STOP reverse
STOP forward
Time
Ramping up Ramping
Forward down
forward
Oil flow from port B STOP AUTO REVERSE

forward is reached
Figure 2 - A & B ports refer to ports on Hydraulic Pump Station
The pistons of the cylinders then move forward again and the process will continue
as described.
The positions FAS and RAS are calculated by the PLC unit on the basis of the ap-
plied set points for RS and FS and the current values of braking and acceleration
cycles and the pump capacities.
In this connection, the PLC unit is programmed for monitoring stroke lengths and
grate speeds and to adjust the pump capacities and FAS-RAS.
Also, the pumps will be swiftly directed towards the ZERO point in case the RS and
FS parameters are exceeded.
The values below must be applied as default set points for the positions and accel-
erations, but they can be adjusted in the PLC unit:
RS = 20 mm
FS = 320 mm
Acceleration and braking cycles can be set in the range of 0-1000 ms. Default it is
set for 200 ms. See instruction manual for electrical equipment.
Adjustments of braking cycles as well as acceleration cycles can be done in the PLC
unit. For example, they may be increased to 300 and 350 m/s if the maximum
capacity of the pump units is not fully utilized. Always remember to increase the
braking cycles in small steps in order to prevent the cylinder from striking against
the bottom.
It is essential to ensure that the limits for the forward and reverse movement are
correctly adjusted in relation to one another, as illustrated in Fig. 2.
70018190-4.0
Page 24 of 32
A fine adjustment is done on the basis of movements registered during normal

operation.
In particular, an adjustment of the acceleration cycles will often be necessary since
they will determine how quickly, and especially the impact with which, the position
of the shuttle valve at the cylinders will be changed.
When making the adjustment, it is essential to ensure that the movement of 300
mm is obtained during normal operation and that the risk of the cylinder "hitting
the bottom" - when the frame is operated at the maximum speed - is eliminated. In
case this is deemed to involve major complications, do not hesitate to contact FLS
to allow minor modifications of the PLC program to be made.
5.4 Pump switching

See description in the instruction manual for electrical equipment.
5.5 Cooling
5.6 Oil heating without starting the hydraulic piston movement

5.7 Manual operation

Once a start command for local control has been given from the central control
room, the drives can be moved backward and forward via the local control cabinet
at the desired velocities. See description in the instruction manual for electrical
equipment.
70018190-4.0
Page 25 of 32
6.0 Maintenance see suppliers manual.
7.0 Remedial action see suppliers manual.
8.0 Appendices
Appendix 1 Main pump with switch-over-block

305 Ball valve 2310 Check valve
310 Axial piston variable pump 2311 Orifice
311 Boost oil filter 4305 Hose
313 Ball valve 4310 Hose
314 Test point 4311 Hose
317 Check valve 4314 Hose
318 Pressure transmitter 4315 Hose
319 Block filter/pump 4465 Hose
320 Electrical motor 4466 Hose
390 Contamination switch
460 Bladder accumulator

465 Accumulator safety block
470 In-line poppet type pressure gauge
471 Pressure gauge
500 Block for stand-by unit

501 Quick coupling
503 Test point
505 Ball valve
510 Pressure gauge
511 In-line poppet type pressure gauge
515 Pressure transmitter
520 Directional valve
525 Check valve, poppet type
530 Logic element
535 Logic element
70018190-4.0
Page 26 of 32
Block 2
Handpump Handpump
Back-up pump B
Back-up pump A
Pre-charge temp
20 deg celsius
Filter
0.5 bar
Contamination switch
max 0.2A
70018190-4.0
Page 27 of 32
Appendix 2 Stand-by pump with flushing filter

292 Pilot operated check valve 505 Ball valve
305 Ball valve 600 Block for flushing filter
310 Axial piston variable pump 605 Check valve
311 Boost oil filter 610 Filter
313 Ball valve 615 Adaptor plate
314 Test point 630 Pressure transmitter
317 Check valve 635 Pressure transmitter
318 Pressure transmitter 640 Test point
319 Block filter/pump
320 Electrical motor 2310 Check valve
390 Contamination switch 2311 Orifice
4305 Hose
460 Bladder accumulator 4312 Hose
465 Accumulator safety block 4313 Hose
470 In-line poppet type pressure gauge 4314 Hose
471 Pressure gauge 4315 Hose
4465 Hose
4466 Hose
4600 Hose
4601 Hose
70018190-4.0
Page 28 of 32
Filter
Filter
Filter
Contamination switch
max 0.2A
0.5 bar
Back-up pump B
Back-up pump A
Figure 3 - For reference only. For specific project, see suppliers manual
70018190-4.0
Page 29 of 32
Appendix 3 Tank and conditioning circuit

100 Oil reservoir 205 Hose saddle
105 Ball valve 210 3 way ball valve
115 Breather filter 220 Electrical motor
118 Inspection cover and seal 225 Screw pump
120 Oil level glass 237 Ball valve
125 Level switch 240 Water cooler
129 Feeler pocket 242 Water valve
130 Temperature transmitter 243 Dirt trap
140 Water oil cooler 250 Filter
142 Water valve 252 Pressure transmitter
143 Dirt trap 260 Ball valve
150 Return line filter 264 In-line poppet type pressure
151 Pressure transmitter gauge
155 Circulation filter 265 Pressure gauge
156 Pressure transmitter 290 Particle counter
170 Heating element 293 Ball valve
190 Hand pump 295 Water detector
194 Quick coupling 299 Junction box
195 Junction box
2140 Check valve
2225 Check valve
2237 Quick coupling
2240 Quick coupling
2245 Check valve
2290 Check valve
2291 Check valve
2292 Test point
4140 Hose
4190 Hose
4210 Suction hose
4225 Hose
4237 Drain hose
4250 Hose
4310 Hose
70018190-4.0
Page 30 of 32
Water detector
Water
Tank monitoring
water detector
particle counter
Filter
Water
particle counter normal

pos.
only flushing
for flushing of Cf pipe
70018190-4.0
Page 31 of 32
Appendix 4 Cylinders with bleed-off valves

0050 Bleed-off valve
0055 Flow switch
7001 Hose
7003 Test point
7020 Straight welding bulkhead
7100 Hose
7103 Test point
7107 Ball valve
7120 Straight welding bulkhead
7205 Ball valve
7210 Hose
7212 Hose
7240 Ball valve for flushing
7251 Hose
70018190-4.0
Page 32 of 32
Transport direction
Return
Switch Rating
Transport direction
Return
Switch Rating
Transport direction
Return
Switch Rating
Transport direction
Return
Rating
Switch
Attention
A ports from HPU is connected to both A and B on cylinders. The same is
for B ports.

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FLSmidth Cross-Bar Cooler

Hydraulic equipment for movement of drives

Operation and maintenance instructions

Created by: CJOE

Definitions and abbreviations

Always follow instruction 19871 Installation, operational preparations and mainte-

1.1 Personal protective equipment

2.0 General Information

Figure 1 - Hydraulic Pump Station

3.0 Construction and operating principle

See Appendix 1Appendix 2Appendix 3Appendix 4

3.1 Hydraulic pumps

3.2 Oil conditioning - booster/servo pump and bleed-off valve

3.3 Servo oil

3.4 Alarms and interlocks

The temperature transmitter (130) features built-in temperature monitoring.

Avoid use of angles, if possible.

Absolutely cleanliness during any work with hydraulic equipment, is of the

5.1 Initial start-up procedure

5.1.1 Hydraulic oil

g) Jog-start pump (225) in order to check the direction of rotation.

5.1.2 Flushing of pipe system

It is of the utmost importance to ensure absolute cleanliness of the oil. It is

Please see guidance in suppliers manual, besides text below.

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

The procedure must be repeated for the other pipe systems.

Maximum cleaning efficiency is achieved if the high oil temperature is maintained,

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

c) Set the pressure limiter at 50 bar on the control cabinet.

h) Check that the speed (spm) is correct.

The stroke length can be increased at subsequent point in time if enhanced

m Repeat the venting operation as described in item f.

5.2 Normal remote-operated starting from centralized control panel

5.2.1 Preconditions for remote-controlled starting

5.3 Controlling of drives - starting position for operation

5.3.1 Operational description

In connection with the adjustment of transducers and checking of movements, it

Oil flow from port A

Oil flow from port B STOP AUTO REVERSE

Figure 2 - A & B ports refer to ports on Hydraulic Pump Station

A fine adjustment is done on the basis of movements registered during normal

5.4 Pump switching

5.6 Oil heating without starting the hydraulic piston movement

5.7 Manual operation

6.0 Maintenance see suppliers manual.

7.0 Remedial action see suppliers manual.

Appendix 1 Main pump with switch-over-block

460 Bladder accumulator

500 Block for stand-by unit

Appendix 2 Stand-by pump with flushing filter

Appendix 3 Tank and conditioning circuit

particle counter normal

Appendix 4 Cylinders with bleed-off valves

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