Troubleshooting

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If your products fail in daily operation and maintenance, you can refer to the following fault description and its reason analysis to troubleshoot problems. Since our product category is various, more information please refer to their instruction manuals or call Diamond Power, we will serve for you with all sincerity.

IR Series Troubleshooting  

Sootblower fails to start:
 • Check that the motor power disconnect switch (or circuit breaker) is closed (on).
 • Ensure all plugs and wires are connected and tight.
 • Verify the motor power source is energized.
 • Check if sootblower has overload alarm and if overload protection is operating properly.
 • Ensure there is control power in the control box.
 • Check if timing relay contact not closed.
 • Check that all sootblowing permissives are met at the control system.
 • Verify proper operation of the rear limit switch and sootblower is in rest position.
 • Verify that the starter actuates when a start is initiated.
 • Try to start the sootblower locally.

 Motor overload alarms is on/higher motor amps than usual:
 • Check that nothing is binding in the gear drive.
 • Wall opening may be slagged over not allowing the nozzle to penetrate.
 • Check that the feed tube packing is not too tight.
 • Check screw tube alignment with front bracket and drive pins.
 • Check that the seal plate in the wallbox is adjusted properly.
 • If the sootblower’s starter is equipped with overloads, check the status of the overload and verify that the current setting matches the motor rating. If the central sootblowing control system performs the current measurements, check system for “Motor Stalled” alarms. If present, check the motor and interconnecting wiring before resetting.

 Motor runs but sootblower does not start:
 •  Check the drive key on motor shaft and gear reducer shaft.
 • Check pins in drive shaft coupling and drive pinion.

 Motor does not reverse at end of blowing revolutions:
 • Check timer relay.
 • Reverse relay coil maybe burned out.
 • Overload contact maybe open.
 • Rear limit switch contact maybe held open.

 Motor reverses but sootblower does not retract:
 • Check front pawl on guide bar and cam engagement.
 • Check drive assembly, pins and keys.

 Drive pins and keys are sheared:
 • Check for nozzle binding in wallbox or wall tubes.
 • Check cam, trigger and guide bar engagement.
 • Check for excessive pipe loads or expansions causing misalignment.

 Steam/air leaking from poppet valve:
 • Check valve stem packing. Tighten or replace packing as needed.
 • Check that feed tube is properly attached.
 • Check feed tube gasket. Replace gasket if needed.
 • Check the connection between the poppet valve and companion flange. Replace the gasket if necessary and torque to 175 ft-lbs ± 25 ft-lbs (237 N-m ± 34 N-m).

 Steam leaking through poppet valve in closed position:
 • Leakage can be detected by a hissing sound in the poppet valve or a warm feed tube when the sootblower has not operated recently.
 • Check that linkage is not binding and can jiggle freely.
 • Check that valve stem packing is properly tightened.
 • Check valve stem condition and alignment.
 • Remove valve and inspect for foreign matter lodged between seat and valve body.
 • Inspect for steam cut or worn seat. Replace with new seat as necessary.

 Poppet valve fails to open/little or no cleaning:
 • Ensure the poppet valve pressure control disc has been properly set.
 • Check the poppet valve trigger and cam operation.
 • Check for interference that might obstruct valve operation.
 • Check that the valve stem packing is not too tight and the stem is not bent.

 Blowing pressure fluctuation:
 • Ensure header pressure is maintaining proper setting at the pressure reducing station.
 • Inspect nozzle for failure.
 • Monitor poppet valve pressure.

 Wall tubes appear damaged:
 • Check blowing pressure.
 • Decrease cleaning revolutions if initially set for more than one revolution.
 • Check nozzle setting and cleaning path.
 • Check for excessive condensate in steam supply.

 Screw tube or feed tube internal corrosion:
 • Check that air relief valve is operating properly to purge boiler gases. Air should be drawn in (negative pressure boiler) or forced (positive pressure boiler).
 • Check that the condensation drain control is functioning properly.

IK Series Troubleshooting 

Steam/air leaking from front of carriage:
• Tighten the six bolts around the lance tube flange to 142 N-m (105 ft-lbs).
• Inspect the condition of the lance tube assembly. A bent lance tube could cause excessive stress on the carriage lance hub connection.
• Inspect the mating surface of the lance and hub flanges. The mating surfaces are the areas that contact the lance tube gasket. The surface should be free of scratches, foreign objects, etc.
• Replace the lance tube gasket.

 Steam/air leaking from back of carriage:
• Replace the feed tube packing.
• Check the condition of the feed tube packing gland. If the packing gland has been allowed to leak, the gland assembly should be thoroughly cleaned and re-packed. Check the condition of the front and rear bushing in the gland assembly.
• Check the condition of the feed tube for deep scratches, raised areas or flat spots. A feed tube in poor condition will greatly increase packing wear.
• Check for bent lance tube that can increase feed tube scratching.

 Steam/air leaking from poppet valve:
• Check valve stem packing. Tighten or replace packing as needed.
• Check that feed tube is properly attached. There should be a small gap between the poppet valve and rear bulkhead. Torque the poppet valve nuts to 156 N-m (115 ft-lbs) in approximately 40 N-m (30 ft-lbs) increments while alternating between nuts.
• Check feed tube gasket. Replace copper gasket if needed.
• Check the connection between the poppet valve and companion flange. Replace the gasket if necessary and torque to 237 N-m ± 34 N-m (175 ft-lbs ± 25 ft-lbs).

 Steam leaking through poppet valve in closed position:
• Leakage can be detected by a hissing sound in the poppet valve or a warm feed tube when the sootblower has not operated recently.
• Check that linkage is not binding and can move freely.
• Check that valve stem packing is not over tightened.
• Check valve stem condition and alignment.
• Check condition of valve stem yoke.
• Remove valve and inspect for foreign matter lodged between seat and valve body.
• Inspect for steam cut or worn seat. Replace with new seat as necessary.

 Sootblower fails to start:
• Check that the motor power disconnect switch (or circuit breaker) is closed (on). 
• Make sure the motor plug is connected. 
• Verify the motor power source is energized.
• Assure there is control power in the sootblower-mounted box. 
• Check that all blowing permissives are met at the control system.
• Verify proper operation of the rear limit switch. 
• Verify that the starter picks up when a start is initiated.
• Try to start the sootblower locally (from the sootblower Start pushbutton).

 Poppet valve fails to open/little or no cleaning:
• Ensure the poppet valve pressure control disc has been properly set.
• Check the turn-on linkage to the poppet valve trigger.
• Check the adjustment of the sootblower turn-on assembly. The stud should enter the mouth of the cam while the carriage is moving in the forward direction as well as the reverse direction.
• Check for interference that might obstruct cylinder or poppet valve motion. 
• Check the pressure setting on the poppet valve.
• Check that the valve stem packing is not over-tightened and that the stem is not bent.

 Motor overload alarms is on/higher motor amps than usual:
• Check the alignment of the carriage.
• Check the oil level in the carriage and grease fill on the hub side of carriage.
• Check that the feed tube packing is not too tight.
• Check for worn pinion gear and bearing.
• Check for worn hub bearings.
• Check that the seal plate in the wallbox is adjusted and floating properly.
• If the sootblower’s starter is equipped with overloads, check the status of the overload and verify that the current setting matches the motor rating. If the central sootblowing control system performs the current measurements, check system for “Motor Stalled” alarms. If present, check the motor and interconnecting wiring before resetting.

 Blowing pressure fluctuation:
• Ensure header pressure is maintaining proper setting at the pressure reducing station.
• Recalibrate or replace pressure switch if supplied.
• Inspect nozzle assembly for failure.
• Installation of new poppet valve will require pressure check.

 Carriage hits the hard stop:
• Check the limit switch.
• Check that the limit switch contacts are operating properly.
• Check that the control system is operating properly.

 Carriage jumps during sootblower travel:
• Check for worn or broken pinion gear.
• Check for worn or broken gear rack.
• Check for bent lance tube.
• Check the rollers on the carriage for flat spots.
• Check the bearings in the rollers.

 Lance tube or feed tube internal corrosion:
• Check that air relief valve is operating properly to purge boiler gases. Air should be drawn in (negative pressure boiler) or forced (positive pressure boiler).
• Check scavenging air pressure.
• Check that the condensation drain control is functioning properly.
• Check sootblower mounting angle. When the boiler is hot the sootblower should tilt forward to allow condensate to drain toward the nozzles.