TP-C305

INSTRUCTION MAUNAI FOR TP-C305

THERMO-PROBE

Jingshan Keneng Boiler Auxiliary Equipment Co., Ltd.

This manual has been prepared for use by competent and knowledgeable personnel
responsible for the operation and maintenance of the equipment. It is imperative that such
personnel thoroughly familiarize themselves with the entire manual before attempting to
install, operate, or maintain the equipment.

It is important to note that this manual contains various warning and caution notes which
should be carefully read in order to minimize the risk of personal injury or the possibility
that improper service methods will be followed which may damage the blower or render it
unsafe. In this manual, Warning constitutes a possible personal injury situation and
Caution constitutes possible blower damage which may render it unsafe. It is also
important to understand that these warnings and cautions are not exhaustive.

This instruction manual has been furnished for use by your own organization only and for
purposes consistent with the transaction between your organization and Jingshan Keneng.
No copies of or data from this manual shall be furnished to any third party without the
written agreement of Jingshan keneng.

This instruction manual may describe variable features not applicable to your specific unit.
If you have any question, please call Jingshan Keneng for solution.


Contents
1

Section 1 General Description

General Description

Working Course

Major technical Data

Section 2 Structure

Gear Train Assembly

Temperature-measuring & Control System

Position Indicating System

Probe Tube Cooling System

Operation & Indicating Instrumentation System

Installation & Commissioning

Initial Installation

Cooling & Sealing Piping

Electric & Instrumentation Wiring

Inspection Before Start-up

Manual Operation Trial Operation

Aligning the Position Indicator

Section 4 Operating Instruction

First Operation

Regular Operation

Inspection Before Operation

Section 5 Maintenance Instruction

Lubrication

Potentiometer Adjustment

Potentiometer Spring Replacement

Thermocouple Replacement

Power & Cooling System Adjustment

Auxiliary Support Adjustment

Automatic Tip Cleaning

Manual Tip Cleaning

Content of Illustrations
1 TP-C305
Figure 1 TP-C305 Thermo-probe Overall View

2 TP-C305
Figure 2 TP-C305 Thermo-probe Installation & Interface Dimensions

3
Figure 3 Probe Tube Assembly

4
Figure 4 Schematic Diagram of Pulley Support Movement

5
Figure 5 Auxiliary Support

6
Figure 6 Position Indicator

7
Figure 7 Schematic of Position-Indicating Circuit

8
Figure 8 Wiring Chart of Thermo-Probe

 9
Figure 9 Position Indicator Instruction tag

10
Figure Potentiometer Spring Replacement

11
Figure 11 Thermocouple Replacement

12
Figure 12 Wiring Layout Chart for Pulley Support

Section 1 General Description

1
General Description
TP-C305
1 2.5 /
1.1KW DCS
The TP-C305 series Thermo-probe is a mechanical device for positioning a
thermocouple element in the furnace gas stream for temperature monitoring (Refer to
Figure 1). The thermocouple is mounted in the end of a probe tube which transverses
into and out of the gas stream with speed of 3m/min during forward and reverse travel.
The thermo-probe is driven by a 1.1 Kw electric motor and can be controlled by a local
or remote push-button station or DCS system.

Gas temperatures in the area just ahead of the superheater tubes at the exit of the furnace
can be critical during boiler start-up before steam circulation is sufficient for cooling.
The thermo-probe, in permitting continuous monitoring of these temperatures, greatly
reduces the danger of heat damage to the tubes. The thermo-probe can also be used to
obtain gas temperatures which are used as an aid in controlling low load operation.
2
Working Course

DCS
DCS

TS-1
TS-2

Carriage drives the probe tube moving forward after start-up of the thermo-probe, and
drives the thermocouple which is mounted in the probe tube entering into the furnace.
The thermocouple transfers the temperature measured to the DCS, and position
indicating system transfers the distance information that thermocouple enters into the
furnace to DCS also. The probe tube stops at the extreme forward position when it
touches the front limit switch, and measures the temperature at the area. The control box
pre-mounted on the thermo-probe can control switch to operate the thermo-probe
moving forward, reversing or stopping at any position. The cooling system will
automatically start up when gas temperature inside the furnace reaches the primary
temperature set (TS-1), and medium flows through the probe tube to cool down the
thermo-probe. When the gas reaches secondary temperature set (TS-2), the thermo-

couple will alarms and automatically reverses, and stops operation after touches rear
limit switch, and the cooling system also stops.

The course is for the thermo-probe with cooling system. Thermo-probe without cooling
system doesnt have the course of start-up and stopping of cooling system.
3
Major Technical Data (Normal design)

Travel
Per Contract

.2
Measuring Range
Refer to the chart, Section 2
WRGKK2-132-HBS500IIE/LB

Thermocouple Specification
L-mm
(L-thermocouple length, mm)
1Cr18Ni9Ti

Probe Tube Material

89

Probe Tube OD.

2.5 /
Moving Speed
2.5 m/min
420mA 0100%
Position Indicating Instrumentation (Advised) 420mA 0100% scale
420mA 0800 K
Temp. Indicating Instrumentation (Advised) 420mA 0800 scale K Scale
Y90S-4 B5 1.1Kw 1400r.p.m

Motor
Y90S-4, B5, 1.1Kw, 1400r.p.m
380V 3P

250Kg+ 115Kg
Approximated Weight
250Kg+115Kgtravel/m
2

Section 2 Structure
1
Gear Train Assembly
TP-C305

The main function of gear train assembly of TP-C305 thermo-couple is to drive the
thermocouple moving into and out of the furnace. The travel is controlled by the limit
switches mounted on both ends of the beam.
TP-C305 C305

545mm
155mm

The dimension of gear train assembly of TP-C305 is close to C305 series sootblowers
and most of parts are in common but the thermo-probes beam is wider (545mm) than
sootblowers beam. To suit with installation space, the probe tube is not located at
center but offsets to one side of the beam. The center of probe tube is 155mm to closer
side of beam. The thermo-probe can be designed as left hand and right hand. View from
rear end, probe tube of left hand offsets to right side and right hand offsets to left side.

Gear train assembly includes beam, carriage, probe tube, manifold, pulley support,
auxiliary support, wallbox, etc.
1
(1) Beam

The beam assembly is a canopy type fabrication that offers support and maximum
protection for all components of the thermo-probe. The tracks and gear racks for
carriage moving are mounted on the both sides of the beam. Bulkheads on each end of
the thermo-probe beam stiffen the beam at the rear and provide a mounting at the front
for the front support bracket. The beam is supported by suspension at two points. The
front support is at the wallbox which is affixed to the boiler. The rear support is located
near the rear of the thermo-probe and is affixed to the building steel.
2
(2) Carriage
1.1Kw Y90S-4B5
C305

The probe tube is driven by means of a traveling motor type carriage. The carriage
consists of a 1.1Kw flange mounted electric motor (Y90s-4-B5) and a gear reducer
which consists of a two-stage gear and a one-stage worm gear and worm stem. Drive
pinions on each end of the gear reducer output shaft engage the racks on each side of the
beam to drive the carriage moving. Structure and maintenance of the carriage refers to
information described in relevant sections in Instruction Manual for C305 Long
Retractable Sootblower.
3
(3) Probe Tube
89
3
The probe tube assembly is fabricated from89 O.D. alloy tubing selected for gas

temperature with three types including non-cooling, air-cooling and water-cooling. For
different types, the structures are different as well. Refer to Figure 3.

The thermocouple is anchored in the front section of the probe tube. The front section is
a protective shield which is closed at the front and threaded at the rear for attachment to
the probe tube. The thermocouple is thus protected from physical damage.

The thermocouple lead wires extend through the probe tube to a junction box located on
the manifold at the rear of the probe tube. The back of the probe tube is closed off with
a manifold block that has been drilled and tapped to accept a packing gland for sealing.
Because of the travel movement, a flexible conductor is provided to bring the signal
from this point to a stationary manifold located at the middle of the beam. Instrument
lead wires are attached at the stationary manifold.
180
300 45

Probe tube assemblies which require air cooling have a cooling inlet at the rear and 4
nozzle outlets near the front. The four nozzles are 180apart positioned 300mm apart
lengthwise on the tube, and slanted 45to the rear. This keeps the cooling air away from
the tip. Cooling air and water is supplied to the probe tube through the stationary
manifold assembly.
4
(4) Manifold

The manifold is located at the middle of the beam. Motor cables, thermocouple lead
wires and cooling hose are connected to the stationary manifold through the pulley
support from the carriage.

Figure 3 Probe Tube

Water Cooling Water Inlet Manifold Tip
Thermocouple Air Cooling Air Inlet
Non-Cooling
5
(5) Pulley Support

4
The pulley support is located under the beam behind the carriage, and moved by the
carriage. Its function is to provide suspension to power cables, compensation

conducting cables and cooling hose, and put them in order on the roller of pulley.
Movement principle of pulley support refers to Figure 4.
4
Figure 4 Schematic Diagram of Pulley Support Movement
Rear Bulkhead Pulley Support Carriage Wire Rope
Manifold Front Bulkhead
Power Cable, Compensation Cable, Cooling Hose, etc.
6

(7) Auxiliary Support

7.6 5
7.6
For travel exceeding 7.6m, a auxiliary support is required at the middle of the beam to

support the probe tube to prevent tube from bending. No the assembly required for
thermo-probe travel under 7.6m.
5
Figure 5 Auxiliary Support
2
Temperature-measuring and Control System

Temperature-measuring and control system includes armored thermocouple mounted in

the probe tube and compensation cable and electric control box of the manifold that
connects to the thermocouple.
3
K

The armored thermocouple is typed dual-branch with 3mm O.D. With different
temperature-measuring range, the material of thermocouple is different. For utility
boilers, the material of thermocouple generally is nickel chromiumnickel silicon (K
scale). Nameplate is attached to the thermocouple. When order new thermocouples,
please follow the description on the nameplate of thermocouple.


TS-1 TS-2

One branch of thermocouple is connected to the temperature transmitter and alarming

relay near the thermo-probe. As required, directly set the temperature on the alarming
relay (TS-1 and TS-2) to control the operation of thermo-probe. Another branch is
directly sent to penal control room for customer receiving signal for displaying
temperature and other purpose.

Temperature-measuring range and travel is related to cooling mode of the probe tube.
Air or water must be provided through the probe tube for cooling when the thermoprobe exceeds certain travel and temperature-measuring range. Information refers to
below table:

Probe

Non-Cooling

Air-Cooling

Water-Cooling

Tube

815

Material

Travel (m)

Travel (m)

Maximum

m /min
3

Gas

Temp. ()

Flow required
at

815
3

(m /min)
1Cr18Ni9

1.5

871

1.5

:8230mm

Ti

3.0

738

3.0

1.4

Maximum Travel: 8230mm

89

4.5

650

4.5

4.2

:1200

6.0

632

6.0

6.3

Maximum Gas temperature:

7.5

610

7.5

8.5

1200

9.5

500

9.5

11.2

Cooling water requirement:

Treated water required.
60
Maximum Water Temp: 60
0.11t/min
Flow: 0.11t/min

815

Note: The table listed for non-cooling thermo-probe with certain travel, the temperature
is maximum measured temperature. For cooling thermo-probe, the cooling medium is
maximum flow at maximum measured temperature 815. The data are calculated as
per regular working, and the probe tube will be retracted when gas reaches the

temperature.

DCS

The electric control box is mounted on one side the beam. For left hand thermo-probe,
the control box is mounted on left side of the beam, and the control box is mounted on
right side of the beam for right hand thermo-probe. Except forward, reverse and stop
functions, the control box shall have interface with computer device and DCS.
1DCS
(1) To computer device, DCS switch signal

Thermo-probe reverses to placeThermo-probe forwards to placeRemote
Control AllowedLocal Control Allowed
2 DCS
2To computer device, DCS to other signal
1 K mV 420mA
K-branch mV temperature signal 420mA position signal
(3) DCS
(3) Control box switch signal from computer control device and DCS
1
Thermo-probe forwardThermo-probe reverseThermo-probe stop
3 6 7
Position Indicating System (Refer to Figure 6 & 7)
10 +10
10

0% 4mA 100%
20mA
The system includes a ten turn potentiometer and position indicator. The ten turn
potentiometer is inserted into the band spring and move it synchronization with band
spring. The ten turn potentiometer rotates with the band spring. It varies the resistance
of the input end of the position transducer which changes the indication and output. The
transducer producers an output from 4 milliamperes and indicates 0% scale when the
probe is fully withdrawn, to 20 milliamperes and 100% scale when the probe is fully
inserted.

 6
Figure 6 Position Potentiometer
7

Figure 7 Schematic of Position-Indicating Circuit

16
Initial position resistance16ohm
470
470 ohm 10-turn potentiometer

Position Indicator
420mA
420mA Output
7 10
W1 Q1

Position indicating circuit refers to Figure 7. In view of the principle that current at
collector of triode can enlarge current at base, when the ten turn potentiometer W1
exerts current Q1 which changes with position of the thermo-probe to base of triode,
current at electrode is enlarged correspondingly, and position of the probe tube can be
shown with instrumentation or indicator.
ZW R3W1R5 R7
R5 4
R3 20
Regulated diode ZW maintains voltage on potentiometers R3, W1, R5 and resistance
stable. The potentiometer R5 is used to adjust zero potential. The transducer produces
an output from 4 milliamperes when the probe is fully withdrawn. The potentiometer is
used to adjust extreme travel. The transducer produces an output to 20 milliamperes
when the probe is fully inserted.
4
Probe Tube Cooling System

Cooling system must be applied when thermo-probe exceed certain travel and
temperature-measuring range. Probe tube cooling system consists of electric valve, hose
and pressure switch, etc. for the purpose of supplying air or water to cool down the
probe tube, and prevent the probe tube from bending or burning damaged at high
temperature. The electric valve controls start-up and shutdown of cooling medium.
Hose is functioned to send cooling medium into the probe tube.

The pressure switch is mounted to ensure adequate flow for protection of the probe

tube. In the event pressure of cooling medium is too low to ensure flow, the thermoprobe cannot be started up, or forwarding probe tube is retracted immediately.
5
Operation & Indicating Instrumentation System

This system means control switches (or buttons), temperature indicators, position
indicators on control panel in control room. Specific parameters refer to Section 1.

Electric elements and instrumentations related to this system will not be supplied by
Jingshan keneng. Customer shall be responsible to overall design the control room,
select right instrumentations, electric elements, and design the control panel.
3

Section 3 Installation & Commissioning

1
Initial Inspection
2

Determine the proper location of each thermo-probe on the boiler as indicated on the
Jingshan Keneng installation drawing or boiler manufacturers standards drawing
provided with each order. Each thermo-probe is supported by suspension at two points
on the beam. The thermo-probe shall keep horizontal in hot position.

Caution: When hoisting the thermo-probe into position, be sure to use the lifting
lugs provided on the top of the beam. Avoid using a sling around the beam as this
could cause damage and subsequent malfunction.

Caution: Remove the packing frame after installation. Otherwise, it could damage
the equipment.

The front support bracket contains two threaded shoulder pins which are inserted into
the holes on the horizontal centering of the wallbox casting. The wallbox casting is
attached to the boiler by a sleeve welded to the boiler wall. Field welding of the wallbox
casting to the wallbox sleeve and the sleeve to the wall must be done before affixing the
thermo-probe to the wallbox assembly.

 2 M24
0.71.4

The rear support bracket consists of a slotted plate welded to each side of the beam. A
rod, passing through the horizontal elongated holes in the two plates, provides the
second supporting point of the thermo-probe. The support rod also passes through a
length of pipe which is welded to the supporting steel and two M24 bolts. Supporting
brackets shall be field welded to the beam based on location of steel building and 0.7
1.4m to the rear end of the bema.

Combination of the two support brackets forms a universal joint type support to permit
the thermo-probe to take the expansion and contraction of the boiler in all three planes.

Caution: The thermo-probe must be supported or suspended on the steel building.

Field weld rear support plates as per location of steel building. Proper welding
methods and protective actions shall be taken to prevent electric cables attached to
the underside of canopy from overheating.

Prior to installation, check the thermo-probe and resolve problems inspected. After
installation and before start-up of the thermo-probe, it is suggested that the thermoprobe be carefully inspected for possible damage from shipment or handling on the job.
Remove all blocking and strapping at this time.
2
Cooling & Sealing Piping

For the thermo-probe with cooling system, all thermo-probe lines are to be blown clear
of all foreign matter before connecting to the operating units. This is to ensure that dirt,
scale, or welding beads from piping system do not enter the thermo-probe. On positive
pressure installations, ensure that the sealing and aspirating air lines are connected and
that sufficient pressure and flow are supplied to accomplish sealing at all boiler loads as
shown on the installation drawing.
3
Electric & Instrumentation Wiring

 8
Power cables, control wire, position indicator and temperature is connected to different
terminals (Figure 8).

Wire power and control cables to control box.

Position indicator is mounted inside the control box.

Compensation cable from temperature indicator to the thermocouple is connected to the

manifold located at the middle of the beam. With different thermocouples, the
compensation cables are different also.
8
Figure 8 Wiring Chart of Thermo-Probe
Remote TransmissionPressure Resistance
Thermocouple
( Motor Power)
To Wiring Box
Chamber
Control Box
Motor Power
Control Power
DCS To alarmingRemote ControlDCS Control Cable

Inspection Before Start-up

Observe alignment of the beam assembly. Check for any bends, twists or other
distortions.

Inspect the thermocouple tip assembly for any damage from handling or shipment.

On positive pressure installation, inspect connection of sealing and aspirating air lines to
ensure pressure and flow.

If the unit is air or water cooled, check the hose connections for pressure tightness.
12 80

Refer to Figure 12 and ensure that all cables and hoses are on the correct pulleys and
have at least 80 mm sag, but do not hang below the bottom of the beam.

Check all the thermocouple junctions for tight terminal connections.

Check all power and control wiring for loosened terminals.

Check the limit switches actuating arms to see that they are thrown in the correct
position for operation.

Prior to operation, lubricate the thermo-probe as described in Sections.

Remove the safety bolt in position indicator.

9
Caution: Ensure that the instructions on the instruction tag in the position
indicator are followed before attempting to operate the thermo-probe assembly.
Failure to do so can result in damage to the position indicator. The tag is illustrated
on Figure 9.
9
Figure 9 Position Indicator Instruction Tag

Before removing this safety bolt, check wire rope on large drum on back of this box.
If wire rope is not tight, loosen jam nut on rope drum, and rotate drum until rope is
tight, then retighten nut. Safety bolt may now be removed. Anytime wire rope is
disconnected, safety bolt must be reinstalled.

5.
Manual Operation & Trial Operation

Note: Power must be shut off before operate the thermo-probe anytime.

After done all inspections before start-up, manual operation can be performed.
Movement is accomplished by turning the square tang, located on the back of the
carriage by a drive socket wrench or electric wrench. Manual operation is to check
performance of the carriage, pulley supports, rollers, probe tube, wirings of pulleys,
cables and hoses. Manual operation provides for moving the carriage to perform normal
maintenance or for removing the probe tube from the boiler in the event of a power
failure or malfunction of the thermo-probe.

Operate the thermo-probe locally to make sure installation of the thermo-probe is proper
and all transmission parts are working correctly, and limit switch actuating arms are at
right place, then supply power to the thermo-probe for operation.

For trial operation, first move the carriage forward a certain distance by means of
manual operation, then supply power to the thermo-probe to check rightness of electric
wiring. After ensure everything is correct in mechanical and electric parts of
transmission system, adjust cooling system, temperature-measuring system and position
indicating system.
6.
Aligning the Position Indicator

Although the potentiometer and the position indicator have been synchronized with the
probe tube position during factory assembly, the meter may have to be recalibrated
because the steel wire rope may get loose during transportation and installation and
need to be re-adjusted and fastened.
6 7
The steps are as follows (refer to Figure 6 and 7):
1 10

16
00
The probe shall be fully withdrawn. Remove the ten turn potentiometer. Adjust it to 16
ohm. Then re-insert it into the band spring. Turn on the control power, motor power.
The position transmitting potentiometer reading should be 0, 0, otherwise adjustment
is necessary.
SETCLK SET
CKI=132 SET5
SETSLL
10 SLL 10-10
SLL 10SET W

Press the key SET, the indicator shall show CLK. Press SET again. The indicator
shows number. Adjust the numbers to make sure CLK=132 and press SET and at
the same time. Five seconds later the meter will go into the second level parameter
setting status. Press SET continuously till numbers appear after SLL. Change the
numbers based on the meter readings. If the meter reading is 10, then minus the
number with 10. If it is -10, then plus 10. Save the settings by pressing SET.
Press the key W (reset) and read the number shows in the indicator. Repeat the above
steps till the indicator shows zero.
2
100100
SET SLH
SLH
SET W
100
Press the Forward button, the probe shall start moving forward until triggers the front
limit switch. The position indicator shall show 100. If it is not 100, then it needs to
be adjusted. Following the same steps above to enter the second level parameter setting
status, press SET continuously till the indicator shows SLH. Change the number
based on the meter readings. Adjust the number correspondingly. Save the settings by
pressing SET. Press the key W (reset) till the indicator shows 100.
3 1315

If the number showed on the indicator decreases and ohm of the potentiometer
increases, or vice verse, exchange the wires marked as 13 and 15.
4

Section 4 Operation Instruction

Generally, the thermo-probe is operated at the point of boiler start-up for short time
operation. However, the operation interval is quite long. Special attention should be paid

to following points in operation.

1
First Operation

Before first operation, trial operation and commissioning must be done. Refer to circuit
description to ensure electric and the thermocouple conjunctions are correct. If the unit
is air or water cooled, make sure adequate pressure and cooling medium flow applied.
On positive pressure boiler, ensure sealing air is supplied to boiler wall interface and
adequate pressure and flow.

Monitor change of travel and temperature in operation. If any abnormity is detected,

eliminate the abnormity in time. Especially, observe if the system alarms and retracts
the probe in time or not when the temperature reaches alarming and retracting
temperature.
2
Regular Operation

The thermo-probe is design to stop the tube but not retracting after engaged with the
front limit switch, and the tube is retracted when reaches the temperature. During the
course of boiler start-up, probably the temperature is not the maximum at where the tip
locates resulted from uneven of temperature. Therefore, it is necessary to manual
operated the thermo-probe to get information of gas temperature intermittently. The best
is to stop the tip at the place that gas temperature is the maximum to prevent local
temperature exceeding, especially when reaches alarming temperature.

Caution: Power for control box, measuring and control system shall not be cut off after
the probe tube moves into the furnace to prevent probe tube from burning damaged after
reaching limit temperature resulted from failure of automatic retracting.
3
Inspection before Operation

Prior to every operation, inspect and maintain the thermo-probe to eliminate detected

problem and perform trial operation, to ensure reliability of mechanical moving system,
position indicating system and cooling system. It is definitely not allowed to operate the
unit before inspection and maintenance. Otherwise, it may damage the unit.
5

Section 5 Maintenance Instruction

1
Lubrication
1
Carriage

All the external moving parts of the carriage are prelubricated bearings. No need to add
lubricant.
30

30# mechanical oil is recommended for carriage gearbox. Other brand lubricant oil can
be used as well depending on the environment and temperature. Change oil fill at one
year intervals depending on the service conditions.
2
Grease Fitting

Fill all grease fittings every year.

3
Motor

Motor has been lubricated before shipping. Normally lubricating is unnecessary for
years. When necessary, remove the cover and fill in high quality speed bearing lubricant
grease.
(4)
Sealing bearings on other moving parts of the probe need no lubricant.
2
Potentiometer Adjustment
8
10

The variable potentiometer used in the position transmitter assembly is limited

mechanically to a maximum of 10 revolutions of the input drive shaft; maximum probe
tube travel utilizes only 8 revolutions. When replacing the potentiometer on right hand
probe illustrated as Figure 10 with the spring wound to the top of the winding drum,
turn its shaft to the limit in a counterclockwise direction (looking from the shaft end),

then advance it half a turn clockwise before mounting. If the unit is left hand, or the
spring winds to the bottom of the winding drum, the shaft of the potentiometer must be
turned in reverse of the above instructions.

Note: This setting is to be made with the probe tube fully retracted.
3
Potentiometer Spring Replacement

The potentiometer spring used to drive the cable pulley, to rewind the cable when the
probe is retracting, is a constant torque motor spring. In the event that this spring fails, it
can be replaced as follows:
10
45

Remove the spring and drum assembly from the position indicator box. Wind the new
spring on the take-up drum as illustrated on Figure 10. Secure the spring to the winding
drum and wind four to five (45) turns of spring on the winding drum. Install the
safety bolt and replace the drum assembly in the position indicator box.

Note: The spring follows its natural bend on the take-up drum, but has a back
ward bend over the winding drum.

2
Attach the cable pulley and wind the cable on the pulley so that it is taunt with the probe
in the retracted position. After the cable is installed, remove the safety bolt and adjust
the potentiometer as instructed in paragraph 2.

10

Figure 10 Potentiometer Spring Replacement

Left Hand Probe
Right Hand Probe
Safety Bolt
Cable Pulley
Wind Drum
Spring
Take-up Drum
Wire Rope
4
Thermocouple Replacement

Caution: When replacing a new thermocouple, included the description stamped on the
thermocouple nameplate which is wired to the junction head.
1

Before replacing the thermocouple, the following check should be made to ensure that
replacement is necessary.
A
Check all wiring for breaks and ensure that all electrical connections are tight.
B 300

With the boiler operation, run the probe tube forward approximately 300mm to place
the thermocouple tip in a higher gas temperature. The temperature readout device
should indicate an increase in temperature if the thermocouple is operating
satisfactorily.

An alternate method is to turn on the aspirating air with the probe tube fully retracted.
The temperature readout device should indicate a decrease in temperature if the
thermocouple is operating satisfactorily.
C

If no change in temperature was indicated from the above check, disconnect the readout
device and monitor the thermocouple signal with a suitable test device to ensure the
readout device is operating satisfactorily.
2

Note: Disconnect motor and control power before proceeding. On positive pressure
installations, turn on the aspirating air to the wallbox before removing the probe
tube.

3 11
Disconnect the thermocouple lead wire illustrated on Figure 11.
4

On the air and water cooled probes, disconnect the hoses at the unions on the carriage.
5
Block up the probe tube near the carriage and at the front support bracket.
6
Remove the screws that fasten the manifold block to the carriage.
7

Slide the probe tube forward until the packing gland clears the carriage and lower the
probe tube. Slide the probe tube back until the tip clears the wallbox. Ensure that the
blocks at the front support bracket will support the tube and not damage the tip as the
tube is pulled off the rollers.
6
Remove the packing gland by unthreading it and sliding it from the thermocouple.

Note: If the thermocouple starts to pull out when removing the gland body, remove the
protective shield at the front and secure the thermocouple in place.
9

Remove the thermocouple protective shield at the tip of the probe tube and remove the
follower from the recess. Dig out the lava seal and replace with a new seal at
reassembly.
10 3

Attach a fish tape to the front tip of the old thermocouple and pull the tape into the
probe tube while pulling the old thermocouple from the rear. Tape the front tip of the
new thermocouple to the fish tape; and with someone guiding it at the rear, pull in into
the probe tube. When the taped portion clears the hole at the front of the probe tube,
stop pulling and remove the tape.
11
Install the new lava seal and replace follower in the front of the probe tube.
12 38 G

Push the thermocouple into the probe tube until 38mm remain exposed. Lubricate the
threads of the protective shield with Molykote G and replace the shield. Tighten the
shield firmly.
13

Reassembly the remaining parts in reverse order.

11
Figure 11 Thermocouple Replacement
Manifold Block
Gland Body
Thermocouple
Sealant
Follower
Packing Gland
Flexible lead
5
Power and Cooling System Adjustment
12 80

The threading procedure for wire rope, power cable, and cooling hoses is illustrated on
Figure 12. The power cable and cooling hoses should have at lease 80 mm sag, but not
hang below the bottom of the beam.
6
Auxiliary Support Adjustment

A periodic check should be made to ensure that the probe tube does not track to either
side of the auxiliary support during forward and reverse travel. If it is necessary,
readjust the auxiliary support.

7
Automatic Tip Cleaning

After certain operation, ash may deposit on the tip to affect measuring. Dirt must be
cleaned before operation.

A tip cleaning feature is supplied as a standard on water cooled and is optional on noncooled and air cooled probes. This tip cleaning is accomplished by directing a puff of air
against the thermal well at the tip of the probe tube.
0.33MPa 15
510
Air for tip cleaning (0.33 MPa initially) is connected to a solenoid valve located at
approximately mid-length near the bottom of the thermo-probe assembly. A signal from
the control system will energize this solenoid for 5 to 10 seconds every 15 minute of
probe operation. These times are adjustable to obtain optimum cleaning.
8
Manual Tip Cleaning

Note: Do not attempt manual tip cleaning on positive pressure boilers while on
line.

When a positive pressure boiler is off-line or on negative pressure boilers, the tip can be
cleaned as follows:
1
Disconnect power supply.
2
Remove the two bolt-on stop blocks located on the sides of the canopy.
3
Using the square tang on the motor, retract the probe until the tip resets on the front
rollers.

Caution: Do not allow the probe tube to drop off the front rollers.
4
Scrape the tip clean with a knife or other sharp instrument.
5

After cleaning the tip, ensure that the probe tube is aligned with the wallbox seal, and
using the square tang, advance the probe tube into the wallbox.
6
Reinstall stop block.

 12
Figure 12 Wiring Layout Chart for Pulley Support
Non-Cooling Air-Cooling Water-Cooling

 Rear Bulkhead Thermocouple Lead Wire Wire Rope

Motor Front Bulkheads Manifold
Motor Power Cable Coupling Air Hose
Water Hose