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Instruction Manual for the Model

C305 Sootblower

华西能源工业股份有限公司
CHINA WESTERN POWER INDUSTRIAL CO.,LTD
京山科能锅炉辅机成套有限公司
Jingshan Keneng Boiler Auxiliary Machine Equipping Co.,
Ltd.

CONTENTS

SECTION 1 GENERAL DESCRIPTION………………


1. General………………
2. Principle of Operation……………
SECTION 2 COMPONENT DESCRIPTION………………
1. Drive Motor………………
2. Carriage………………
3. Poppet Valve………………
4. Beam………………………
5. Wallbox………………………
6. Power Supply………………
7. Lance and Feed Tube Support………………
8. Front Support Brackat………………………
9. Feed Tube ……………………………
10. Lance Tube………………………………
11. Nozzle………………………
12. Controls……………………
13. Porgressive Helix Mechanism ( optional )
SEVTION 3 INSTALLATION INSTRUCTIONS……………………
1. Blower Assembly……………………………………
2. Aspirating and Sealing Air ……………………
3. Piping………………………………
4. Gaskets ………………
5. Valve Condensate Drain Line………………
6. Power Supply………………………………
7. Scavenging Air………………………………
8. Adjusting Blowing Pressure………………
9. Wallbox Purge ( Recovery Boilers ) ………………
SECTION 4 PRE-OPERATING INSTRUCTIONS……………………
1. Operating Precautions and Blowing Schedule………
2. Inspection Before Start -up…………………………
3. Initial Operation…………………………
SECTION 5 MAINTENANCE INSTRUCTIONS………………………
1. Manual Movement of Carriage……………………
2. Feed Tube Packing……………………
3. Lance and Feed Tube Removal……………………
4. Poppet Valve and Turn-on Linkage……………………
5. Carriage Removal……………………
6. Carriage Disassembly
7. Carriage Reassembly
8. Progressive helix Mechanism Replacement
9. Expanda Cable Replacement Porcedure-C305-525
10. Expanda Cable Replacement Procedure-C305-545
11. Hose Carrier Removal DELETED
12. Disassembly of Hose Carrier DELETED
13. Assembly of Hose Carrier DELETED
14. Lubrication Instructions

ILLUSTRATIONS

Figure1 Model C305-525 Sootblower , overall view


Figure2 Nozzle Coeaning Pattern-4″Helix
Figure3 Gear Train Schematic
Figure4 Proper Position of Rollers
Figure5 Air Motor Control Valve
Figure6 Progressive Helix Mechanism-Left Hand
Figure7 Carriage Rear View
Figure8 Non-Asbestos , Graphite Fiber , and Graphite Foil Packing Installation
Figure9 Attachment of Feed Tube
Figure10 Blowing Medium Turn-on Linkage
Figure11 Adjustable Pressure Control Procedure
Figure12 Carriage Disassembly
Figure13 Worm Gear Shimming Procedure
Figure14 Progressive Helix Mechanism
Figure15 Expands Cable Replacement-C305-525
Figure17 Hose Carrier Disassembly DELETED
Figure18 Threading Procedure-Hose DELETED
Figure19 Lubrication Schematic
Figure20 Sight Gauge Oil Level for Carriage Gear Case
SECTION 1
GENERAL DESCRIOTION

1. General
The Model C305-525 and C305-545 Sootblowers are applied to the cleaning of
heating surfaces of boilers fired with ash producing fuels . Refer to Figure 1 for an
overall view of the C305-525 blower . The blowers are principally used to remove
slag and ash deposits from slag screens , superheaters , reheaters , and economizers .
They are also used to clean deposits from the underside of the furnace arches and for
cleaning tubular air heaters.
Individual components and parts identification of the sootblowers for each contract
are illustr on the forms attached to the rear of these instructions .
2. Principle of Operation
a. Cleaning Principle
The basic principle of the sootblower is the cleaning lf the heating surfaces by
multiple impacts of high pressure air or steam from one or more nozzle openings
located at the end of a long translating-rotating lance tube . The path of each nozzle is
a helix . Helices of 4″ , 6″, or8″can be used ,depending on the length of the blower
and the intended service . When the sootblower reverses , the lance indexes enabling
the bisects the helical path of the forward travel . Nozzle paths with two nozzles and a
4″helix blower are illustrated on Figure 2 .
If the optional “ progressive helix mechanism ”is incorporated in the soot-blower ,
the constant repeatable nozzle paths will be eliminated . This mechanism predictably
indexes the nozzle paths on each blower cycle . On an C305-525 with a 4″helix , the
lance indexes about 47.409。 at the start of
each blower cycle and will only repeat exact paths after 449 cycles .

1"SHIFT AT REVERSE

o1

NOZZLE 1 RETARCTING
EXTENDING
NOZZLE 1 RETARCTING
EXTENDING

Figure 2 Nozzle Cleaning Pattern-4"Helix


b. Primary Elements
(1) An efficient nozzle-especially selected for each application .
(2) A means to convey the nozzle-conveying mechanism includes the lance tube ,
carriage , and drive motor .
(3) A means to supply blowing medium to the nozzle-poppet valve , reed tube ,
packing gland , and lance rude .
(4) A means to vupport and contain the blower components-a canopy –type beam
wity a two point point suspension .
(5) Controls-integral components protected by the beam to control the blowing
cycle and supply power to the
C. Blower Operation
The sootblowing cycle begins with the blower in the retraced position as illustrated
on the drive motor , it will move the carriage along the guide rails located on each
side of the beam to project the lance tube into the boiler . When the nozzle is inside
the boiler , the carriage will turn on the blowing medium valve to begin the cleaning
cycle . The carriage will continue to translate and rotate the lance trbe into the boiler
until it reaches the carriage will reverse its direction and at the same time index the
lance tube to return on a different nozzle path . The carriage will continue to retract
until the nozzle is near the blowing medium is shut off . The carriage then continues
to the retracted position .

SECTION 2
GOMPONEVT DESCRIOTION

1. Drive Motor
a . Electric
The electric motor normally operates on 230/460 volts . The motor is 1-1/2
horsepower , 1725 rpm and has a NEMA C flange that mounts directly to the
carriage .
b . Air (C305-525 only)
The air motor operates on approximately 45 scfm at 80-100 psig air pressure at the
motor inlet . The motor has a NEMA C flange with a cast iron housing that mounts
directly to the carriage .
2. Carriage
The carriage assembly drives the blower lance tube into and out of the boiler . It
contains the drive motor , gear box , and a packing gland which confines the blowing
medium in the lance and feed tubes .
The motor drives a set of spur gears for a primary reduction or increase in speed to
the main gear box . These gears are external to the main gear box . and readily
accessible for changing the single train speeds of the carriage when the helix is
changed , it will also be necessary to change the translation spur gear set . The gear
train is illustrated on Figure 3 . The standard travel speeds and helices are . listed are
indicated on the carriage parts identification form .
Trave Lance
Speed Helices Tube RPM
35 in/min . 4 8.5
70in/min 4 17.6
100in/min 4 25.7
140in/min 4 34.0
70in/min 8 8.5
100in/min 8 12.5
140in/min 8 17.6
70in/min 6 12.5
NOTE : Travel speeds may increase slightly on air motor operated blowers .
The primary output shaft from the primary spur gears drives a worm set in the main
gear box for the major speed reduction . The output shaft from the primary worm set
operates spur gears for translation and bevel gears for rotation of the lance tube .
The carriage hub contains the mounting flange for the lance tube and a packing
gland to seal the feed tube . The carriage is completely sealed for maximum protection
from dirt and corrosive atmosphere .
3. Poppet Valve
The mechanically operated poppet valve is located at the extreme rear of the blower
. This valve can be used with steam or air as the blowing medium and has an
adjustabje pressure control. The opening and closing of this valve is automatically
controlled by the travel of the blower carriage . An adjustable trip pin on the carriage
assembly operates the cam and arm assembly to automatically open or close the
poppet valve to supply the blowing medium when the lance tube is in the blowing
position . The trip pin is illustrated on Figure 7. The valve will close automatically
when the unit has retracted to the non-blowing position .
Speciai applications may require that the poppet valve be replaced with a
diaphragm operated blowing medium admission valve.
Figure 3 Gear Train Schematic

4. Beam
The beam assembly is a canopy-type fabrication that offers support and maximum
protection for all components of the blower . Bulkheads on each end of the blower
beam support the poppet valve and feed tube on the rear and the lance tube support on
the front . The beam is supported at two points . The front support is normally at the
wallbox which is affixed to the boiler casing . The blower and is affixed to the
building steel . This method of support permits the blower to take the expansion and
contraction of the boiler in all three planes . Some applications may require that the
beam be completely supported from building steel .
5. Wallbox
Each wallbox contains two holes located on a horizontal line . Shoulder bolts from
the front support enter these holes and transfer the load (approximately one-half
soothlower weight ) to the wallbox . The type lf wallbox depends upon whether the
blower is installed on a positive or negative pressure boiler . Each type of wallbox is
described below .
a. Negative Pressure Wallbox
The negative pressure wallbox contains an external spring loaded seal plate that
seals around the lance tube and allows for boiler expansion . The wallbox casting is
welded to a sleeve that is mounted to the boiler casing . On recovery boilers , a special
wallbox with purge connections is supplied .
b . Positive Pressure Wallbox
The positive pressure wallbox provides sealing around the lance tube when the
lance tube is in place . It also provides for aspiration of the port hole when the lance is
removed for service . When the lance tube is in place . low pressure seal air enters the
wallbox and prexsueizes the chamber . This piessurization of the wallbox keeps the
boiler gases from escaping . The seal air flows into the boiler and out to the
atmosphere between the lance tube and seal rings .
The seal ring on the boiler side of the wallbox is also an aspirating ring . It is a
venturi shaped ring with holes drilled around the circumference . When it is necessary
to remove the lance tube , high pressure air is admitted to the wallbox . As this air
flows through the holes in the aspirating ring , itdraws atmospheric air into the boiler
thereby sealing the opening .
6. Power Supply
a. Electri Motor
power is supplied to the traveling motor by a drop cord , an Expanda – Cable , or a
multiple loop cable , The drop cord forms a loop between a junction box on the side
of the blower and the motor . The Expanda – Cable is located in the upper section of
the blower beam .The multiple loop able assembly is located to ome side or below the
blo9wer beam .
b. Aor Motor (C305 –525 only )
Power is supplied to the traveling motor by means of a hose carrier , coiled hose ,
or a hanging loop , The hose carrier is mounted in the upper section of the blower
beam . The hose carrier is mounted in the upper section of the blower beam . The
coiled hose is located to one side or below the beam .
7. Lance and Feed Tube Support
The lance and feed tube support is located near the midpoint of the blower beam on
blowers with travel exceeding 25 feet . It supports both the lance and feed tube during
the first half of forward travel and only the feed tube during the last half of forward
travel .
8. Front Support Bracket
The front support bracket is located at the front of the blower beam and affixed
to the wallbox casting . This bracket carries approximately one-half the blower weight
and contains rollers at its base that support and guide the lance tube through the
wallbox and into the boiler . It is important to maintain proper adjustment of these
rollers in relation to the lance tube helix as illustrated on Figure 4.
DIRECTION OF LANCE ROTATION DIRECTION OF LANCE ROTATION
DURING FORWARD TRAVEL DURING FORWARD TRAVEL

LOOKING TOWARD BOILER


R.H.BLOWER R.H.BLOWER

Figure 4 Proper Positioning of Rollers

9. Feed Tube
The feed tube is a highly polished stainless steel tube used to supply the blowing
medium to the lance tube . For specific applications , the feed tube may be chrome
plated to increase surface harbness.
10. Lance Tube
Lance tubes are made of different types of steel depending on the requirements of
each sootblower If there is more than one type of lance tube on a boiler , it is
important to install , the correct lance tube in each location . The lance tube is
supported at the carriage and , at the front of the blower .Blowers with travel
exceeding 25 feet have an additional support near the midpoint of the blower beam .
The two rollers on the front support bracket are adjusted to rotate at the same angle as
the lance tube helix .
11. Nozzle
The lance tube contains a spun closed nozzle block with openings that are
positioned vertical , lead ,or lag depending upon the cleaning application . The size
and number of the openings are determined by the blowing medium flow and pressure
requirements for each sootblower location . It is important to install the correct nozzle
in each location The nozzles are balanced at the factory to ensure equal thrust from
the opposing jets to prevent lance whipping .
12. Controls
The electric motor driven blower has limit switches located at the front and rear of
the blower beam to control the forward and reverse travel . These switches are
actuated by a trip pin located on the carriage as illustrated on Figure 7 The air motor
driven blower has a motor control the forward and reverse travel . The snap action
device of the air motor control valve is actuated by trip blocks located at the front and
rear of the rear of the blower beam .
SECTION 3
INSTALLATILN INSTRUCTIONS

1. Blower assembly
Determine the proper location of each sootblower on the boiler as indicated on the
Diamond installation drawing or boiler manufacturer’s standard drawing provided
With each order . Each blower is supported at the boiler by suspension at two points
on the blower beam .
CAUTION: When hoisting the blower into position , be sure to use the lifting
lugs provided on the top of the blower beam . Avold using a sling around the
beam and lance tube as this coulb cause damage and subsequent malfunction .
The front support bracket contains two threaded shoulder pins which are inserted
into the holes located near the horizontal centerline of the wallbox casting .
The wallbox casting is fastened to the boiler by a sleeve welded to the boiler wall .
Field welding of the wallbox casting to the wallbox sleeve must be done before
affixing the blower to the wallbox assembly .
The rear support bracket consists of a slotted plate welded to each side of the
blower beam as illustrated on Figure 1 . A rod , passing through , the horizontal
elongated holes in the two plates , provides the second holes in the two plates ,
provides the second supporting point of the blower . The support rod also passes
through a length of pipe which is welded to the supporting steel .
The combination of the two support brackets forms a universal joint-type support to
permit the blower to take the expansion and contraction of the boiler in all three
planes . Some applications may require that the blower be completely supported form
building steel .
Blowers using air as a blowing medium are generally mounted so that they are
horizontal when the boiler is in operation . Blowers using steam as the blowing
medium are generally sloped towards the boiler to allow drainage of nozzle block .
The installation drawing gives the information required for mounting a blower on a
hot or cold boiler .
A flexible sealing gasket is supplied with each blower assembly . See paragraph 4
for gasket installation instructions .
2. Aspirating and Sealing Air (Positive Pressure Boilers ).
External piping connections are provided to supply aspirating and sealing air to the
plenum chamber of the wallbox . Attachment to the wallbox should be made
with2″connection should be supplied with seal air from the forced draft fan or a
separate installation drawing . The 1″ pipe size connection at the plug cock valve
should be adaptable for connection to an 80to 100 psig compressed air source to
perform the aspirating function . Air consumption is dependent upon the amount of
furnace pressure against which this opening must be sealed .
3. Piping
The piping to the blowers most not be less than the size specified on the installation
drawing . To promote proper drainage of condensate , all steam piping must have a
pitch of at least 1/2 inch per foot toward the discharge end of the drain line .
All sootblower lines are to be blown clear of all foreign units . To do this , remove
the drain valve and disconnect the blowers at the flanges of the cleaning medium
supply line . Separate the flanges and insert a sheet metal deflector between the
flanges during the “blowing out ” process . This is to ensure that dirt , scale , or
welding beads from the piping system do not enter the blowers .
Piping must be designed to prevent undue strain on the sootblower .
4. Gaskets
When installing gaskets between sootblower flanges , all bolting should be
tightened evenly . It is not essential to use a torque wrench since the gaskets are
equipped with a gauging ring Tightening should be in several steps in a criss-cross
pattern until the flange faces contact the gauging ring .
Care should be taken to assure that flanges are not cocked . This would result in
unequal compression of the gasket and early failure . Once gasket compression is
started in a wedge configuration , the spiral rings may be deformed making it
impossible to obtain a satisfactory seal .
CAUTION : Do not overtlghten studs . Approximate torque values when
properly tightened will be 175 foot-pounds .
5. Valve Condensate Drain Line
Any steam blowing C305 sootblower with its blowing medium value installed more
than 45° off vertical centerline requires a condensate drain line . A condensate drain
line is normally not supplied on blowers used on small package boilers or oil heaters .
The drain line relieves the condensate which wonld otherwise be trapped between
the valve seat and the companion flange . This drainage eliminates the temperature
differential created by the presence of the condensate , maintaining a more uniform
blowing medium valve body temperature , and preventing condensate buildup in the
valve which can contribute to corrosion and increased condensate carryover at the
start of blowing . The drain line enters the companion flange via a socket weld
connection to avoid hazard to personnel . Refer to installation drawing for drain line
configuration .
6. Scavenging Air
Scavenging air is a means of keeping out or scavenging the corrosive furnace gases
from the blower when it is not operating . For this purpose ,all blowers have an air
relief valve on the poppet valve .
On negative pressure installations , atmospheric pressure provides a sufficient flow
of room air through the air relief valve and blower ; but on positive pressure
installations , it is necessary source to the air relief valve to overcome furnace
pressure . Refer to installation drawing for required differential prevents the escape of
the blowing medium from the blower into the room or into the forced draft line while
the blower is operating .
7. Power Connection
On some installations ,the electric motor starters are individually mounted on each
blower ; others have the starters remotely located in a common enclosure . In either
case ,there will be provisions in the blower terminal box for a power connection .
Refer to the schematic interconnecting drawing furnished with each contract .
For air motor driven blowers . the pwer air is normally connected at the rear lf the
blower , but this can vary for special application .
The electric terminal boxes and starter enclosures are shipped from the factory with
bags of moisture absorbent to protect the electrical hardware during storage ing damp
atmospheres . The se bags should be checked periodically and replaced during
extended storage periods .
8. Adjusting Blowing Pressure
The sootblower is equipped with an adjustable with an adjustable pressure control
on the downstream side of the poppet valve seat . This is the means for reducing the
blowing medium supply pressuer to the desired blowing pressure . This pressure
control is opened approximately one turn at the factory during assembly and must be
set in the field .
Consult the sootblower location drawing for the recommended blowing pressures
for each blower location The adjustable pressure control procedure is illustrated on
Figure 11 .
When a steam generator is first placed into service , the tube surfaces will have an
immunity to ash and slag adherense . Consequently , it will appear at first that the
recommended blowing pressures are higher than required . During this perio’d ,
lasting for a few weeks , it may not be mecessary to operate the blower very often .
Later , after the tube surfaces have acquired a thin coating of residual slag , the
depoits of slag and ash will be more difficult to clean and the recommended ,blowing
pressures will more than lC305ely be repuired .
9. Wallbox Purge ( Recovery Bollers )
blowers for recovery boiler applications are provided with piping from the poppet
valve to the wallbox for purging the salt cake buildup . This Line is energized when
the valve admits steam to the lance tube during the blowing cycle .
The purge piping assembly includes an orifice that is predrilled at the factory .
According to the severity of salt cake buildup ,it may be necessary to enlarge the hole
size of the orifice to increase the steam pressure at the wallbox ; however , excessive
pressure could result in steam cutting the lance tube and wallbox sleeve .

SECTION 4
PRE-OPERATING INS TRUCTIONS

1. Operating Precautions and Blowing Schedule


Long retractable blowers are generally used on boilers of relatively high steaming
capacity , but can be used on smaller boilers . The larger capacity boiler is normally
large enough in furnace volume that the amount of cleaning medium blown into it is a
small percent of the gases passing through it . On a smaller boiler , the amount of
cleaning medium blown into it could be large enough to cause “ puffing ” or agitation
of combustibles which might accumulate in pockets and behind baffles . Sootblowers
useb on smaller boilers must be operated with caution to prevent the danger of puffing
or furnace explosion . With the larger boilers , these precautions are not normally
necessary .
Precautions should be taken on smaller boilers to ensure that the boiler is steaming
at a capacity of over 50 precent , and draft fans are operating at a high rate of flow , If
agitation of combustibles occurs , this will assure they are carried through the boiler at
a rapid rate . If the firing rate is low ,puffing or furnace explosions are possible .

The normal recommended practice is to clean the boiler in the direction of gas flow.
The units near the furnace operate first, followed by the superheater and economizer
units. If it is anticipated that very heavy accumulations must be removed, a few of the
units in the rear passes should be operated interchangeably with those in the first pass
of the boiler. This will eliminate a heavy accumulation in the boiler outlet area. If a
“straight through”schedule were employed, it is conceivable that accumulation
removed from the superheater region would pile up in the economizer area. These
recommendations are simply general-operating experience with the individual boiler
will be the most accurate guide.
2.Inspection Before Start-up
After installation and before start-up of the blower, it is suggested that the blower
be carefully inspected for possible damage from shipment or handling on the job.
Remove all blocking and strapping at this time.
Check the blower for proper location and mounting. The blowers are shipped
lubricated at all grease fittings, but less oil in the carriage gear case. Fill the gear case
with the oil specified in the Lubricant Chart located in the parts identification section.
CAUTION: It is extremely Important that the carriage drive pinions are in
alignment with the two gear racks to prevent abnormal stress loads at the lance-
hub joint and keep rack wear to a minimum.
Carriage alignment may be checked by removing the inspection plates on both
sides of the beam and measuring from the rear of the beam to the tool center holes in
both ends of the pinion shaft. Because of normal production tolerances, these two
measurements could vary as much as 1/4” ; however, a greater variance would
indicate pinions were not engaged with corresponding adjacent rack teeth.
On all blowers shipped after July 1977, witness arrows have been welded to each
side of the beam, directly over each inspection plate. These arrows have been located
from corresponding teeth on each gear rack. To eliminate the need for inspection plate
removal, a slot has been made in the plate for viewing the tool center hole in the
pinion shaft. Also, to assist in aligning the tool center hole with the arrow point, a
vertical witness line has been added to the inspection plate, along with instructions for
checking carriage alignment.
CAUTION:Disconnect power supply to motor before attempting to re-align
the carriage.
If misalignment is indicated, reposition the carriage until it aligns. This can be done
by removing one of the removable pieces of track angle and repositioning that side of
the carriage.
If misalignment is indicated and the optional progressive helix mechanism is
installed on the blower, manually move the carriage forward 4 to 5 inches and return
to the rest position. The carriage should now be aligned properly.
WARNING:The poppet valve safety guard is affixed to the rear of the beam
assembly to guard against injuries such as burns and mechanical pinches and
should be removed only for maintenance purposes and then replaced.
3.Initial Operation
Before operating an electric motor driven blower, disconnect the power supply and
manually advance the carriage by turning the square tang until the carriage is clear of
the square tang until the carriage is clear of the rear limit switch. Check the front and
rear limit switches for freedom of operation and ensure that the switches are left in the
proper position to accept the actuating pin located on the carriage.
If the optional progressive helix mechanism is installed on the blower, manually
advance the carriage 4 to 5 inches and return to the rest position while making certain
the carriage pinions index one tootn.
CAUTION: Prior to energizing any electronic control panel, all field wiring
must be meggered to ground. In addition, each wire should be traced from the
control panel to its point of termination.
Reconnect the power supply and check the motor for proper direction of rotation.
The blower is now ready to be put into operation. Start the blower by actuating the
manual push-button station and after a few feet of forward travel, manually flip the
forward limit switch to ensure that the blower will reverse.
CAUTION : Be sure the forward limit switch is returned to the proper
position to accept the carriage actuating pin for the next forward travel.
Start the air motor driven blower by actuating the manual push-button station and
after a few feet for forward travel, manually trip the motor control valve to ensure that
the blower will reverse. The blower will return to the rest position where the motor
control valve will automatically rest for the next forward travel. If the blower does not
have a manual push button, it can be started by turning the handle on the diaphragm
control valve counterclockwise until the blower starts. Reset the diaphragm valve by
turning its handle to its extreme clockwise position.
Blowers should now be operated to check for possible binding or abnormal
operation. Verify that the lance tube is in proper contact with the front support
bracket. Following successful operation, blowers should be operated from the control
panel several times for a final check of sequential operation.
After operating the blowers several times, all pressure sealing points listed below
should be checked for proper tightness. This is especially important when superheated
steam is used as the blowing medium. Check gasket tightness for the first three points
and refer to Section 5 for tightening of feed tube packing.
Pressure Sealing points
1.Poppet Valve and Companion Flange
2.Feed Tube and Poppet Valve
3.Lance Tube Flange
4.Feed Tube Packing
SECTION 5
MAINTENANCE INSTRUCTIONS
WARNING : If the pooppet valve safety guard is removed for maintenance
purposes, it should be reinstalled before returning the blower to service.
1.Manual Movement of Carriage
WARNING:Disconnect power supply before manually operating carriage.
All blowers contain a means for manually transmitting power to the blower
carriage. This facility provides for moving the carriage to perform normal
maintenance or for removing the lance tube from the boiler in the vevnt of a power
failure of malfunction of the blower. Movement is accomplished by turning the square
tang located on the rear of the carriage by a 5/8” drive socket wrench or and air
wrench. The square tang is illustrated on Figure 7 .
Do not apply more than 60 ft-lbs of torque to the square tang. Excessive torque may
damage internal components of the carriage. If a force greater than 60 ft-lbs is
required to move the carriage, attach a come-along to assist in the manual movements.
CAUTION : Do not operate the come-along as an independent means for
manual movement because the carriage has self-locking features. The square
tang must be turned while operating the come-along.
WARNING : Before performing any work requiring removal of the poppet
valve, close the main blowing medium supply valve and open poppet valve to
release pressure.
2.Feed Tube packing
WARNING:Before removing feed tube packing, shut off steam supply line to
the poppet valve. Disconnect the power source to prevent automatic operation of
the blower and possible electrical shock.
a. General
The feed tube packing, which provides a seal between the stationary feed tube and
the translating lance hub, is contained in a stuffing box in the area indicated on
Fighure 7. The adjustable packing gland should be tightened only enough to trevent
excessive leakage. Excexxive tightening of the packing gland will shorten the life of
the packing and increase the loading on the carriage. On applications where
superheated steam is primarily used as the blowing medium, final adjustment of
packing tightness should be made after operation of the blower when the feed tube is
at ist hottest condition. This will ensure greater packing life and prevent
overtightening due to the thermal expansion. Some leakage of steam or water
condensate is normal at the start of blower travel.
The feed tube is highly finished to provide a satisfactory sealing surface and should be
protected from damage during maintenance. If the feed tube is detached from the
beam, care should be taken in reassembling to ensure that the feed tube is centered in
the lance hub packing bushing. The bushing should enter the lance hub without any
offcenter binding when the feed tube is properly located. Proper alignment must be
maintained to avoid scoring the feed tube or causing premature wear of the packing.
The stuffing box contains multiple rings of packing. Many types of packing are
available and many have been tested and evaluated from the sootblower application
viewpoint. The sootblower application viewpoint. The following data represents this
viewpoint.
b. End Rings
Two rings of different cross-section provide seating at each end of the packing set.
Therefore, the packing set consists of both the first and the last ring having a different
shape. End rings are sometimes of different material or style. This is required for
increased strength because of gland bushing loading. Also end rings are sometimes
split when middle rings are endless, or vice versa, because of the style of the end ring.
End rings do not appear sensitive to being split or endless construction. Sometimes
end rings require wire reinforcement for adequate strength. When used, the wire is in
the core only and is covered by the outer packing material to minimize ist tendency to
scratch the O.D. of the feed tube.
c. Split Versus Endless Rings
A packing set may have split or endless rings. Most endless rings give substantially
longer life but are more difficult to replace than split rings. Rings, in this case, mean
the middle(multiple) rings, not end rings. Woven construction rings do not appear
sensitive to being split or endless. However, most molded graphite rings do appear,
most molded are always supplied in the endless ring design. The molded chevron
shaped teflon rings are always supplied for ease of replacement.
d. Temperature Limits
Packing sets are divided into two temperature limit categories of high or low
temperature. These limits are based upon feed tube skin temperature. The low
temperature category limit is 500F and the high temperature category limit is 850F
Since temperature limits are based on feed tube skin(outside diameter) temperature,
sometimes an insulated feed tube can be utilized allowing use of low temperature
packing at higher steam temperatures. In rare instances where steam temperature
exceeds 850F, high temperature packing can be used with insulated feed tubes. Low
temperature packing type is chevron style Teflon. This packing gives significantly
longer life than standard high temperature packing types under the same conditions
within the allowable temperature limit. High temperature packings are offered in
many different non-asbestos materials, graphite foil, graphite fiber, and the standard
non-asbestos which consists of either a fiberglass jacket or a carbon fiber spun jacket.
e. Materials
Four types of packing materials are available. These are as follows:
Teflon : Recommended low temperature packing. Chevron style is flexible
allowing self-compensation for excellent sealing with minimum gland loading.
Lowest friction material due to its lubricity. Maintains polished finish of feed tube
surface better than other packing. Glass filled for increased strength and molybdenum
disulfide filled for additional lubrication. Woven Teflon end rings are used for better
contact stress distribution with the packing bushing preventing early failure of the end
rings.
Non-Asbestos : Low cost high temperature asbestos-free packing. A braided
fiberglass jacket with a buna binder over a special asbestos-free core impregnated
with graphite. Conical style middle rings for maximum pressure balance. End rings
only contain inconel wire for added strength. Split rings are used for easy
replacement.
Graphite Fiber:Optional asbestos substitute. High temperature braided yarn with
each strand treated with TFE dispersion. Split rings are used for easy replacement
because endless rings of this braided yarn show little improvement in service life.
Service life is approximately equal to non-asbestos type.
Graphite Foil : Superior service high temperature packing optional on most
sootblowers. Flexible all-graphite ribbon foil packing containing no resin binders or
inorganic fillers. High density conical ring style pressure formed with interlocking
“W” construction for maximum strength. Generally packing rings are not degraded
but are worn away; therefore, rings are not replaced-just added as needed.
Generally they do not require retightening after out-of-service water washing.
Endless rings are provided in original equipment sootblowers and are highly
recommended for service replacement because service life is more than double that of
split rings. Service life should be much greater than any other high temperature
packing thus offsetting the higher cost of installation of the endless rings.
CAUTION:Use only the packing recommended by Diamond Power.
f.Packing Set Part Numbers
For part numbers of recommended packing sets see attached parts identification
Form 3841.
g.Lubrication
In general, in-service lubrication of the feed tube, in an attempt to lubricate the
packing, is not recommended. Some particular circumstances, such as air blowing
with standard nonasbestos packing, may benefit somewhat in keeping the packing soft
and flexible but usually the lubricant will be scraped off by the first ring and only
leaves an oil or grease film on the feed tube to attract fly ash. The detrimental abrasive
affect of this fly ash far exceeds any slight lubricant addition to the first ring or two of
the packing.
Lubrication of the individual packing rings upon installation can be helpful in
easing installation and lubricating during break-in. Specific instructions, depending
upon packing type, follow in “Installation” instructions.
h.Packing Tool Part Numbers
Tools are available for installing individual packing rings. These are highly
recommended for maximum packing life. For part numbers of available tools see
attached parts identification Form 3335.
WARNING:Shut off steam supply line to the poppet valve and disconnect the
power source before proceeding.
i.Split Ring Non-Asbestos and Graphite Fiber Packing Installation
(1)To provide ease of inserting packing into the stuffing box, it is recommended
that a solution of lightweight oil and moly-grease be brushed on individual rings
before insertion. This will provide more flexibility to the packing and protective
coating during the breaking-in stage, but is not to be used as a normal packing
lubricant. A packing tool, machined to conform to the shape of the packing, should be
used to facilitate the packing installation.
(2) Manually advance carriage forward a few inches for better working clearance, if
desirable.
WARNING:If steam shut-off is not done as instructed in the above warning, or,
leakage exists in the shutoff, do not abvance the carriage far enough to trigger the
poppet valve and allow blowing medium turn-on.
(3)Refer to Figure 7 and unbolt the packing gland. Slide it to the rear of the feed
tube for maximum working clearance.
(4)Remove the old packing with a flexible packing hook. Direct the hook at the
bore of the stuffing box to avoid damaging the feed tube.
(5) Carefully clean the stuffing box, gland, and all components. A solvent may be
required to remove all traces of residue.
(6)Inspect the feed tube and stuffing box for scratches, nicks, and wear. Repair or
replace any damaged parts.
(7)Brush each packing ring with a solution of lightweight oil and moly-grease.
Lay each ring in its proper sequence for installation as illustrated on Figure 8.

POPPET

VALVE

PACKING GLAND

PACKING FEED TUBE

Figure 8 Non-Asbestos,Graphite Fiber,and Graphite foil Packing

(8)Use both hands to fit one ring at a time on the feed tube. Grasp the packing ring
with the diagonal cut held upward. Separate the packing ring enouth to engage it
around the feed tube and gently start it into the stuffing box, indexing the diagonal cut
90°with the preceding ring.
(9)Clamp the packing tool around the feed tube with the beveled end toward the
stuffing box. Lay each ring into place as it is entered into the stuffing box.
CAUTION : Do not attempt to insert a ring which has become cocked or
rolled under. To do so could easily deform or damage it to the extent that it would
no longer provide an effective seal.
(10)When installing the last or end ring of packing, reverse the packing tool placing
the squared end toward the stuffing box. Remove the packing tool, slide the packing
gland into position, and evenly tighten the gland nuts. Do not overtighten. After
several operations on newly installed packing, retighten the gland nuts until the gland
is firmly seated against the packing with minimum leakage on reverse(out of boiler)
travel.
j.Endless Ring Graphite Foil Packing Installation
(1)The use of a lubricant at assembly is generally not recommended. However, a
minimum quantity of moly-grease or graphite powder can be used if desired. A
packing tool, machined to conform to the shape of the packing, should be used to
facilitate the packing installation.
(2)Manually advance carriage forward a few inches for better working clearance.
WARNINE : If steam shut-off is not done as instructed in the previous
warning, or leakage exists in the shut-off, do not advance the carriage far enough
to trigger the poppet valve and allow blowing medium turn-on.
(3)If old packing is not graphite foil type, remove the old packing with a flexible
packing hook. Direct the hook at the bore of the stuffing box to avold damaging the
feed tube.
(4)If the old packing is graphite foil type and does not appear to be damaged or
extruded, one or two new rings of packing may be added to refill the packing chamber
to its normal level.
(5)Refer to lance and feed tube removal section of this manual. Follow directions
for feed tube removal only; the lance tube does not have to be removed. The feed tube
is not “removed” but merely unfastened to allow endless packing ring installation.
(6)Carefully clean the stuffing box, gland, and all components. A solvent may be
required to remove all traces of residue.
(7)Inspect the feed tube and stuffing box for scratches, nicks ,and wear. Repair or
replace any damaged parts.
(8)Lay each ring in its proper sequence for installation as illustrated on Figure 8.
(9)Very carefully, so as not to damage 1.D. of packing ring, place each ring of
packing over end of feed tube. Reinstall feed tube. Care should be taken not to cross
thread the feed tube nut on “early design”installations.
(10)Clamp the packing tool around the feed tube with the beveled end toward the
stuffing box. Tamp each ring into place as it is entered into the stuffing box.
CAUTION : Do not attempt to insert a ring which has become cocked or
rolled under. To do so could easily deform or damage it to the extent that it would
no longer provide an effective seal.
(11)When installing the last or end ring of packing, reverse the packing tool placing
the square end toward the stuffing box. Remove the packing tool, slide the packing
gland into position, and evenly tighten the gland nuts. Tighten gland nuts to 50 inlbs.
After several operations on newly installed packing, retighten the gland nuts to
maintain the 50 in-lb loading so that there is no leakage on reverse(out of boiler)
travel.
k.Teflon Packing Installation
(1)Teflon packing is a pressure seal arrangement. The blowing medium pressure
spreads the lips of the chevron shaped rings against the O.D. of the feed tube and l.D.
of the packing chamber to effect the seal. UnlC305e other styles of packing which
rely on the packing gland to load the packing rings, the gland for teflon packing
serves only to control the packing chamber depth to account for manufacturing
tolerances in the overall length of the packing set.
(2)Manually advance carriage forward a few inches for better working clearance.
WARNING : If steam shut-off is not done as instructed in the previous
warning, or leakage exists in the shut-off, do not advance the carriage far enough
to trigger the poppet valve and allow blowing medium turn-on.
(3)Refer to Figure 7 and unbolt the packing gland. Slide it to the rear of the feed
tube for maximum working clearance.
(4)Remove the old packing with a flexible packing hook. Direct the hook at the
bore of the stuffing box to avoid damaging the feed tube.
(5)Carefully clean the stuffing box, gland, and all components. A solvent may be
required to remove all traces of residue.
(6)Inspect the feed tube and stuffing box for scratches, nicks, and wear. Repair or
replace any damaged parts.
(7)The use of a lubricant at assembly is generally not recommended. However, a
minimum quantity of moly-grease or graphite powder can be used if desired. A
packing tool, machined to conform to the shape of the packing, should be used to
facilitate the packing installation.
(8)Lay each ring in its proper sequence for installation as illustrated on Figure 8a.
(9)The lips of these rings are particularly vulnerable to damage and extra care
should be taken while inserting them into the packing chamber.
(10)If split ring packing is being used, use both hands to fit one ring at a time on the
feed tube. Grasp the packing ring with the diagonal cut held upward. Separate the
packing ring enough to engage around the feed tube and gently start it into the stuffing
box indexing the diagonal cut 90°with the preceding ring.
(11)If endless packing rings are being used, refer to the lance and feed tube removal
section of this manual. Follow directions for feed tube removal only; the lance tube
does not have to be removed. The feed tube is not“removed”but merely unfastened to
allow endless packing ring installation.
(12)Very carefully, so as not to damage I.D. of packing ring, place each ring of
packing over the end of feed tube. Reinstall feed tube. Care should be taken not to
cross thread the feed tube nut on“early design”installations.
(13)When installing the last or end ring of packing, reverse the packing tool placing
the squared end toward the stuffing box.
(14)After the last ring is in place, the packing gland should be brought up finger
tight against the packing; then, take up one full turn of the packing gland nuts to
ensure a good seal at the lips. Do not overtighten. After several operations on newly
installed packing, retighten the gland nuts until the gland is firmly seated against the
packing with minimum leakage on reverse(out of boiler) travel.
3.Lance and Feed Tube Removal
WARNING:Shut off steam supply line to the poppet valve and disconnect the
power source before proceeding.
a.Figure 9 illustrates the attachment of feed tube to the blower beam and poppet
valve. Remove the poppet valve mounting 3/4” stud nuts. Slide the valve retaining
plate forward on the feed tube and remove the key from the feed tube keyway.
b.Refer to paragraph 2 and remove the feed tube packing.
c.For blowers fabricated before October 1976, unthread the feed tube from the
feed tube flange located in the poppet valve mounting plate. Push the feed tube
forward until the threaded end is well into the stuffing box.
For blowers fabricated after October 1976, the feed tube flange has been relocated
on the forward side of the poppet valve support plate to facilitate feed tube removal
and replacement and reduce the probability of cross threading. For this arrangement,
remove the two 3/8” hex head screws in addition to the four 3/4” stud nuts discussed
in step a. above. The feed tube flange can then be threaded onto or off the feed tube
without rotating the feed tube.
NOTE:An alternate method of disconnecting the feed tube flange is to shut off the
blowing medium supply and remove the poppet valve. This will expose the feed tube
flange and permit it to be unthreaded from the feed tube. It may be necessary to exert
force to the center of the lance tube, especially on longer travel blowers, to decrease
natural lance/feed tube droop, aiding feed tube removal or installation and minimizing
feed tube thread damage.

WARNING : Before performing any work requiring removal of the poppet


valve, close the main blowing medium supply valve and open poppet valve to
release pressure.
d.On blowers exceeding 25 feet travel, the cross braces of the beam and the lance
and feed tube support must be removed.
e.Remove the six retaining bolts from the lance flange. With the lance and feed
tubes securely supported by a hoist, move them forward from the hub flange enouth to
clear the carriage when lowering. The lance tube may be moved in either direction by
rotating the lance tube with a strap wrench.
WARNING:As soon as lance tube is pulled from hub flange on plus pressure
boilers, stuffing should be installed in end of lance and feed tube to protect
maintenance personnel from furnace gas entering through nozzle end of lance
tube.
f.Reassemble in reverse order. The feed tube must be threaded into the feed tube
flange far enough to provide approximately 1/16-1/32” gap between the face of the
poppet valve and the valve mounting plate. The location of the feed tube flange from
the end of the feed tube is illustrated on Figure 9.
CAUTION:When reinstalling feed tube into poppet valve, ensure that steam
turn-on linkage adjustment has not been affected and will operate properly. If
necessary, readjust per paragraph 4.
NOTE : Blowers with 2-3/4” O.D. feed tubes fabricated after mid 1979 have
socket head cap screws instead of the studs and nuts illustrated on Figure 9. Two studs
may be temporarily used to align and support the valve while two of the cap screws
are threaded in.
When replacing the six retaining bolts in the lance flange, lubricate the threads and
underside of screw heads with high-temperature lubricant. Evenly and alternately,
torque the bolts to approximately 100 ft-lbs.
NOTE:If the hub flange was removed, there should also be a 1/8” gap between
the hub flange and the lance flange when reassembling.
NOTE:After operating the blowers several times, the lance tube and feed tube
gasketed joints and the feed tube packing should be retightened.

4.Poppet Valve and Turn-on Linkage


Blowing medium supply to the blower lance is normally controlled by a mechanical
poppet-type valve. This valve is attached to the blower assembly and is opened
through a cam linkage attached to the beam. This linkage is operated after the blower
carriage has moved forward a given distance from its normal rest position. Adjustment
of the “turn-on”point is accomplished by properly locating the trip which engages the
cam.
CAUTION:The trip bar assembly must be located on the carriage to provide
8-3/4” dimension from centerline of carriage to rear end of the trip bar assembly.
The turn-on linkage must be adjusted so that the trip pin on the carriage enters the
mouth of the cam during forward travel. Figure 10 illustrates correct adjustment. If the
cam position indicates the arm is too long, remove the shoulder bolt from the block
and trigger of the poppet valve, loosen the lock nuts, and thread the block farther onto
the arm. Unthread the block if the cam position indicates the arm is too short. Also
check the linkage for freedom of movement. Freedom of movement is achieved by
adjusting the position of the pivot block assembly.
WARNING : Do not hand operate the linkage with poppet valve under
pressure.
The poppet valve contains an adjustable orifice disc which provides a means of
adjusting the valve outlet pressure. To increase the downstream pressure, remove the
lock pin and rotate the fluted disc to produce a larger flow area. To reduce the
pressure, simply lower the disc. A screwdriver or similar object can be used to insert
into the fluted disc for turning. Refer to Figure 11 for adjustable pressure control
procedure.
When setting pressures with high temperature steam, it is sometimes necessary to
take special precautions to keep the pressure gauge from being damaged. A looped
piece of pipe should be used to connect the gauge to the poppet valve. This looped
pipe should be filled with water and the gauge should be mounted in a position below
the pressure tap on the valve body. If a nipple and union are used to attach the looped
pipe to the valve body, the gauge can be mounted without losing the water.
WARNING:Do not attempt to adjust while valve is open.
When the valve does not remain steam tight when closed, it is an indication that the
seat and disc mating faces are steam cut or warped. This condition can usually be
corrected by regrinding and lapping. Refer to the form in the parts identification
section for lapping procedure. This form also includes instructions for replacing
welded seats if grinding and lapping do not correct the damage to the seating surfaces.
The required special tools mentioned in the procedure are illustrated on separate
forms also in the parts identification section.
5.Carriage Removal
a . Disconnect the electric power supply at the drive motor. On air operated
blowers, disconnect the air source upstream of the motor control valve.
b.Refer to paragraph 3 and remove the lance and feed tubes.
c.On electric operated blowers, remove the limit switch trip pin that is located
near the top of the carriage housing. On air operated blowers, remove the stationary
section of the trip-out valve from the side of the beam. Push the stationary section to
the rear of the blower enough to break valve connection.
d.Support the carriage by means of a hoist through the access hole in the top of
AIR RELIEF VALVE

REMOVE PLUG
TO CONNECT
GAUGE

LOCK-PLUG
ADJUSTING DISC

NOTE: TO INCREASE PRESSURE,TURN DISC COUNTERCLOCKWISE.


TO DECREASE PRESSURE,TURN DISC CLOCKWISE.
1.REMOVE PIPE PLUG AND CONNECT GAUGE.
2.OPERATE BLOWER TO OBTAIN READING.
3.REMOVE LOCK-PLUG AND ADJUST DISC.(SEE WARNING NOTE ABOVE.)
4.REPLACE LOCK-PLUG AND OPERATE BLOWER FOR PRESSURE READING.
5.REPEAT IF NECESSARY UNTIL DESIRED PRESSURE HAS BEEN OBTAINED.

NOTE:AFTER ADJUSTING PRESSURE,BE SURE ADJUSTING DISC HAS A


FLUTE LOCATED SO AS TO ACCEPT LOCK-PLUG.

Figure 11 Adjustable Pressure Control Procedure

the beam. Remove the two short carriage support angles at the rear of the beam
and lower the carriage.
e.Reassemble in reverse order.
CAUTION : Before installing carriage to blower assembly, see allgnment
checking procedure in Section 4, paragraph 2.
6.Carriage Disassembly
The following instructions are divided for partial or complete disassembly,
depending on the component or components requiring attention. Refer to paragraph 5
when carriage removal is necessary and Figures 12 and 13 for disassembly and
reassembly reference.
a.Motor and Change Gear Assembly
For removal of motor and change gear housing, proceed as follews:
(1)Remove the 1/2” pipe plug. Detail 50, from the bottom of the carriage housing
and Detail 69 from bottom of change gear housing. Lower the oil level to the base of
the oil sight gauge, Detail 60.
(2)Remove the six 3/8” cap screws, Detail 10, and pull the motor and housing,
Detail 9, straight back to disengage the change gears.
(3)The motor spur gear, Detail 61, is secured to the motor shaft by the elastic stop
nut, Detail 11.
(4)The worm shaft spur gear, Detail 12, is secured by a retaining ring, Detail 62.
(5)When replacing the assembly, coat both sides of the gasket, Detail 13, and
threads of the six cap screws, Detail 10, with nonhardening gasket cement.
(6)Raise the motor and change gear housing, Detail 9, to the upper most position,
within the clearance of the cap screw holes, to ensure maximum running clearance
between the motor spur gear and the wormshaft spur gear before tightening the six
cap screws.
b.Lance Hub, Bearing, Bevel Gear, and Pinion Gear
(1)Remove the 1/2” pipe plug, Detail 66, in the bottom of the lance hub cavity and
drain all oil from the lance hub cavity if optional oil bath lubrication is used.
(2)Remove the packing gland, Detail 1, and hub flange, Detail 2, from the lance
hub, Detail 46.
(3)Remove the four 5/8” hex head cap screws, Detail 3, securing the front bearing
retainer, Detail 54, to the carriage housing, Detail 48, and remove the bearing retainer
and gasket, Detail 8.
(4) Withdraw the lance hub, Detail 46, bearing, Detail 63, and bevel gear, Detail 7,
from the front of carriage housing as an assembly.
(5)Remove the four 5/8” hex head cap screws, Detail 3, securing the rear bearing
retainer, Detail 47, to the other end of the carriage housing and remove the bearing
retainer, Detail 47, gasket, Detail 8, and the rear lance hub bearing, Detail 63.
(6)If optional oil bath lance hub lubrication is used, oil seals are press fit into both
bearing retainer plates. The lip of the seal should be checked for cuts or curling due to
overheating.
(7)The pinion gear, Detail 5, is held to the shaft, Detail 6, by a key, Detail 64, and a
slip fit.
(8)Inspect bevel gear and pinion for wear and galling and check condition of
bearings.
NOTE : On non-rotating blower carriages the gear, Detail 7, and bevel pinion,
Detail 5, have been deleted and the lance hub bearings replaced with appropriate
spacers.
(9)reassemble in reverse order. Be sure the bearings are positioned with the shields
facing outward. Before replacing, coat the retainer gaskets, Detail 8, on both sides
with non-hardening gasket cement for a leakproof seal. Lubricate the 5/8” cap screws,
Detail 3, with moly-lube or similar material to facilitate future removal. Lubricate the
seal lip or rope packing with carriage oil.
c.Drive Pinion, Pinion Shaft, and Spur Gear Assembly
(1)Remove drive pinions as discussed in paragraph 6. d.
(2)Remove carriage housing cover, Detail 34.
(3)Remove retaining ring, Detail 35, securing bearing, Detail 36, to the outer
carriage support lug.
(4) Spread retaining ring, Detail 37, and slide along shaft to end of keyway. Be
careful not to stretch ring out of shape.
(5)Whth a rawhide mallet, drive the pinion shaft, Detail 31, toward the lance hub
side of carriage. As the shaft is removed, the outboard bearing, seal, inboard bearing,
and key, Details 36,49,38,and 39 will accompany it leaving the gear in the housing.
CAUTION: As the end of the shaft passes through the gear, be prepared to
take off the retaining ring before it drops to the bottom of the carriage housing.
(6)Reassemble in reverse order. When passing the shaft through the gear, position
the keyways of the shaft and gear upward. As shaft protrudes through the gear, install
the retaining ring, Detail 37, and move it toward the nearend of the keyway as the
shaft is seated into place. When reinstalling, lubricate the seal lip and mating shaft
with carriage oil.
NOTE:Extreme care must be taken during their reassembly to prevent damage to
the seal lip.
(7)Insert key, Detail 39, in keyway of pinion shaft, Detail 31, and slide into gear,
detail 50. Move retaining ring, Detail 37, into groove next to gear hub. Be sure ring is
seated.
(8)Replace support bearing retaining ring, Detail 35, drive pinion, Detail 30, and
housing cover. Be sure retaining ring, Detail 32, is properly seated in groove.
d.Carriage Rollers and Drive Pinions
CAUTION : Before removing pinions, note their positions for reassembly
purposes. Refer to step (4) below.
(1)The rollers, Detail 29, and pinions, Detail 30, may be removed from each end of
the main pinion shaft, Detail 31, by removing the retainer rings, Detail 32.
(2)The ball bearings. Detail 65, are secured in the rollers by retainer rings, Detail
33.
(3)Inspect condition of bearings for fiat spots, etc. , by rotating inner race relative to
outer race. The bearings are pregreased and shielded and cannot be relubricated.
CAUTION:Use only the replacement bearings from Diamond as they contain
special lubricant required for successful operation.
(4)Inspect pinion teeth for wear before reassembly. One face of each rack pinion is
marked with an“O”(former practice) or an “X”(current practice). To maintain the
original tooth wear patterns, make sure the pinions are reinstalled on the same end of
the shaft and the marks on the pinions are facing in the same direction as they were
before removal.
(5)Reassemble in reverse order noting the following special instructions.
e.Wrom Shaft Assembly
(1)Remove motor and change gear assembly as discussed in paragraph 6.a.
(2)Remove worm shaft spur gear as outlined in paragraph 6.a.
(3)Remove the four 5/16” cap screws, Detail 14, and withdraw the shaft, bearing,
spacer, and retainer, Details 15,16,17,and 18 as a unit.
(4)Check condition of bearings, worm teeth, and shaft seal, Detail 19, before
replacing. If bearing. If bearing retainer, Detail 20, is removed to replace shaft seal, be
sure to include all shims, Details 21, 22, and 23, as these provide proper bearing
clearance as discussed in Figure 13. Install Detail 17 with flat towards bottom of
carriage. When reinstalling, lubricate the seal lip and mating shaft with carriage oil.
NOTE:Extreme care must be taken during their reassembly to prevent damage to
the seal lip.
(5) Replace motor and change gear assembly.
f.Worm Gear, Spur Gear, and Bearing Carrier Assembly
(1) Remove both 1/2” pipe plugs, Details 59 and 66, in the bottom of the carriage
housing and drain all oil from both cavities.
(2) Remove the bevel pinion, Detail 5, as outlined in paragraph 6. b.(This step is
not required for nonrotating blowers.)
(3)Remove the worm shaft as outlined in paragraph 6.e.
(4)Remove the six 5/16” hex head cap screws, Detail 24, securing the bearing
carrier, Detail 25, to the carriage housing and withdraw the worm gear, spur gear,
shaft, and bearing, Detail 51, as a unit. Components can only be removed from the
threaded end of the shaft.
NOTE:On blowers having a 4” helix, gear, Detail 50, must be moved to provide
clearance for removal of bearing, Detail 51. Slide retaining ring, Detail 37, away from
gear, Detail 50, allowing gear to slide towards outside of housing cavity thereby
providing clearance for bearing, Detail 51.
(5)Remove cap screws, Detail 67, to remove housing, Detail 40, to gain access to
locknut, Detail 68, for complete disassembly of shaft, Detail 6.
(6)Inspect bearings, seals, and gear teeth giving special attention to wear pattern of
the bronze worm gear. If worm gear requires replacement, see Figure 13 for proper
shimming procedure.
(7)Replace parts in reverse order using shims, Details 42, 43, and 44, to minimize
shaft endplay as shown in Figure 12. Face casting number of worm gear away from
bearing carrier housing. Be careful to include all shimgaskets, Details 26,27, and 28,
with the bearing carrier since they govern the proper position of the worm gear
relative to the worm. Seem preceding paragraph(6). Coat bearing carrier cap screw
threads with non-hardening gasket cement before replacing. When reinstalling,
lubricate the seal lips and mating shaft with carriage oil.
NOTE:Extreme care must be taken during their reassembly to prevent damage to
the seal lips.
NOTE:For worm gear shimming procedure, see Figure 13.
7.Carrlage Reassembly
The carriage should be reassembled in the reverse order of disassembly instructions
6. a. through 6. f. This order of assembly will eliminate interference problems with
each previously assembled group or parts.
Note that each disassembly group has specific reassembly instructions in the last
few paragraphs of each subassembly group. See Figure 12 “Carriage
Disassembly”and Figure 13“Worm Gear Shimming Procedure.”
Refer to specific lubrication instructions in this manual for the carriage assembly.
Fill both the main gear case and the lance hub gear case of the carriage assembly with
the recommended quality and quantity of lubricant.
8.Progressive Helix Mechanism Replacement
a.Manually advance the carriage approximately six inches.
NOTE:If carriage/lance cannot be advanced, it may be necessary to remove or
lower the carriage assembly.
b . Remove two cap screws, lock washers, and hex nuts from each progressive
helix mechanism and remove the mechanisms.
c.Rebuild or replace the mechanisms as required.
d . Clamp a short piece of rack between the progressive helix mechanism and
the blower rack to obtain correct spacing prior to tightening the cap screws. See
Figure 14. If it is necessary to replace the stationary rack section or the track angle,
these parts should be welded to the track angle or beam shell respectively after
adjustment.

9.Expanda Cable replacement Procedure C305-525


a.Disconnect power source to blower.
b.Uncouple quick disconnects at each end of expanda cable, Details 1 and 2.
Refer to Figure 15.

BOILER END BLOWER

Figure 15 Expanda Cable Replacment

c.Unbolt cone mounting bar, Detail 3, from tow bar assembly, Detail 4.
d . Remove cable retainer clamps, Details 5 and 6, from first and last loop of
expanda cable.
e.Remove nuts, Detail 7, which hold suspension rod, Detail 8, at boiler end of
blower.
f.Expanda cable, Detail 9, can now be slipped off boiler end of suspension rod.
g. Reassemble with new expanda cable in reverse order maintaining the dimensions
specified in notes A, B, and C on illustration.
When replacing an expanda cable, Detail 9, adjustment of the suspension rod,
Detail 8, and control cone, Detail 10, is usually necessary. The following procedure
should be used:
a.Tighten nuts on suspension rod ends to 30 in-lbs, or until rod can be deflected
approximately 1/2” at mid-span with a 10 to 15 pound force.
b.With the carriage in the rest position, adjust(using slots in cone mounting bar,
Detail 3 ) the position of the cone horizontally and vertically to coincide with the
position of the rod. The nylatron slider, Detail 11, which is fastened to the front of the
cone may touch but not deflect the rod.

c.Check the position of the small end of the cone relative to the rod. It should be
centered horizontally and the rod should clear the bottom of the groove in the cone by
1/16” to 3/16”. It may be necessary to bend the cone support structure to accomplish
the proper adjustment. Care should be taken tosupport the member being bent in order
to keep the strain off the bolts which attach the tow bar assembly, Detail 4, to the
carriage assembly.
d.Operate the blower and carefully observe the cone position relative to the rod.
The tip of the cone may rub the rod at various points throughout the travel. Some
rubbing is acceptable but should be minimized at the point of carriage reversal. Aftre
the cycle is completed, readjust the position of the cone if necessary.
WARNING:Do not switch expanda cable ends and connections to cause male
end to be electrically charged when disconnected.
h.When replacing the expanda cable, it is advisable to check other components
for worn parts. The reaction wheel, Detail 9, should be replaced if the radial play
between it and the shoulder screw, Detail 11, exceeds 1/16”. The leaf springs, Details
13, 14, and 15, should be replaced if cracked or broken. The slider block, Detail 16,
should be replaced if it is worn so that the aluminum part of the loop control
assembly, Detail 17, contacts the suspension rod, Detail 7.
i.Reassemble with new expanda cable maintaining the dimensions in Notes A and
B on illustration. To aid in the bolting of the support bracket to the carriage, loosen set
screw, Detail 10, and remove reaction wheel, Detail 9.
WARNING:Do not switch expanda cable ends and connections to cause male
end to be electrically charged when disconnected.
j.The brass nuts at the end of the suspension rod should be torqued to 90 to 100
in-lbs. The suspension rod should be restrained from turning when tightening the nuts.
CAUTION:Use only brass nuts at each end of the suspension rod. This is a
safety measure to prevent breakage of the suspension rod.
k . The blower should be operated and the functioning of the expanda cable
assembly carefully observed after assembly of the expanda cable assembly. The points
to be observed are the following.
(1)Proper pull-out of expanda cable at full fravel. Check clearance between the
suspensin rod and the first few coils behind knob. The clearance should be 1/4”
minimum.
(2) Check to see that the coils of expanda cable do not drag on upper track angle
during retract. It coils drag, check tightness of suspension rod.
11.Lubrication Instructions
(Refer to Figure 19)
CAUTION : In compliance with transportation codes, blowers must be
shipped with oil drained from gear cases. Be sure to add lubricant to the carriage
gear case before operating the equipment.
NOTE:The lubricant chart referred to below is located in the parts identification
section.
a.Cariage Assembly
All external moving parts contain prelubricated sealed bearings. It is not expected
that these bearings will require additional lubrication. In extraordinary cases where
the lubrication is depleted, such as cookout from leaking lance joint or packing, it may
be necessary to replace these bearings.
The standard carriage gear case should be filled to a point approximately 1”
above the centerline of the square tang on the worm shaft or to a point approximately
2-5/8” from the centerline of the gauge mounting hole to the top of the oil level in the
viewing glass (see Figure 20) with the lubricant specified in the Lubrication Chart
(120 fluid oz.)
NOTE:For vertical blowers only. The change gear housing is pre-packed with
grease at the factory. A grease fitting is provided in the housing for adding lubrication
when required.
The lance hub bearings are pregreased at the factory. Grease fittings are provided in
each bearing retainer plate for adding lubrication when required. The frequency of
lubrication will depend on the severity of blower operation.
The lance hub cavity in the standard carriage is pre-packed with lubricant at the
factory. On blowers shipped before June 1972, it is necessary to remove the lance hub,
bearing, and bevel gear assembly to re-pack the cavity. Later blower carriages have an
inspection plate for this purpose.
If optional oil lubricated lance hub carriage gear case is used, the lance hub carriage
gear case should be filled to a point approximately 3/4” above center line of the gauge
mouting hole (see Figure 20). Use lubricant specified in the Lubrication Chart in the
parts identification section (approximately 20 fluid oz.).
NOTE:Non-rotating blowers to not require lubrication in the lance hub cavity.
b.Drive Motor
(1)Electric Moto – The drive motor contains prelubricated sealed bearings. These
are life-of-the-motor bearings and, therefore, no provision has been made for
lubrication fittings.
(2) Air Motor – The air motor contains ball bearings that are lubricated by the air
line lubricator. Should additional lubrication be required for the rear bearing, remove
the plug and install a standard lubrication fitting. Refer to the Lubrication Chart and
use the lubricant specified for general lubrication fittings.
c.Gear Rack
Lubricate the gear rack approximately every six months with lubricant specified in
the Lubrication Chart. The frequency of lubrication will depend upon severity of
blower operation.
d.Front Support bracket
The bearings on the rollers of the support bracket are pregreased at the factory.
Grease fittings or optional grease cups are provided for additional greasing
approximately every 90 days. Use lubricant specified in the Lubricant Chart. The
frequency of lubrication will depend on the severity of blower operation. When grease
cups are supplied, follow the procedure listed below for reinstallation of part.
(1)Install a grease fitting on the roller shaft and lube until grease is visible at roller
bearings.
(2)Remove grease fitting and replace with lubricator(903305-0005).
(3)Fill lubricator reservoir until grease flows out of small vent hole in side of
lubricator body.
Simply installing the lubricator on the roller shaft and filling until criteria in Step 3
is met, does not assure that the bearing and lubricator are both full. Proper lubrication
requires all steps be followed in sequence.
e.Progressive Helix Mechanism
The mechanisms are pregreased at the factory. One grease fitting is provided on
each side. The frequency of lubrication will depend upon the severity of blower
operation.

型吹灰器单台控制原理图
Principle Drawing for Model C305 Single Control Box
后行程开关 前行程开关
控制箱 Back Limit Switch Front Limit Switch
Control Box

前进接触器 后退接触器
Forward Contactor Backward Contactor

型本体电气箱
Sootblower Body Control Box
前进按钮Forward Button

后退按钮Backward Button
现场隔
离开关
Partition
Switch

至电机
动力电源 反馈信号 公共跳线(仅限于单台控制箱)
Power Feedback Public Line
To Motor
Signal

注:图示吹灰器处于初始停止位置,后行程开关处于受压状态;图中D为前进启动脉冲,A为吹灰运行信号公共总线,A1为吹灰控制
总线,A2为后退控制总线,A3为启动控制总线,ZK为总控制开关(用于单控与程控的转换),GK为就地控制开关。
Note:The sootblower show in the pictture is in its original stop position and the back limit switch is under pressure.In this picture ,D:Running
Start Pulse,A:Running Signal Public Bus,A1:Control Bus,A2:Backward Control Bus,A3:Start Control Bus,ZK:General Control Switch,GK:Local Control
Switch.