Instruction Manual For Thermo Probe - Rev.1

DOCUMENT SUBMISSION STATUS: FOR INFORMATION
1 22.06.2018 FOR INFORMATION J.S.CHOI T.G.LEE S.I.HONG

0 10.10.2017 FOR INFORMATION J.S.CHOI T.G.LEE S.I.HONG
REV DATE DESCRIPTION PREPARED CHECKED APPROVED
PROJECT TITLE
SONG HAU 1 THERMAL POWER PLANT (2x600MW)
OWNER OWNER’S CONSULTANT
VIETNAM OIL AND GAS GROUP (PVN) FICHTNER GmbH & Co. KG PV ENGINEERING
EPC CONTRACTOR EPC CONTRACTOR’S CONSULTANT
VIETNAM MACHINERY INSTALLATION TOKYO ELECTRIC POWER SERVICES

CORPORATION (LILAMA) COMPANY LIMITED - TEPSCO
SUB-CONTRACTOR
DATE NAME SIGN DOCUMENT TITLE
PREPARED 22.06.2018 J.S.CHOI
INSTRUCTION MANUAL
22.06.2018
FOR THERMO PROBE
CHECKED T.G.LEE
APPROVED 22.06.2018 S.I.HONG
DOCUMENT NO. REV.

SH1-DHI-P1HCB-M-M01-MAN-1586 1
INSTRUCTION MANUAL
DIAMOND TP500-E
THERMOPROBE
Temperature Sensor
Contract N11836
Diamond Power Specialty Limited

Block 10, Vale of Leven Indy. Est., FAILURE TO COMPLY WITH THE
Dumbarton. INSTALLATION, MAINTENANCE &
Scotland G82 3AD
LUBRICATION INSTRUCTIONS
CONTAINED WITHIN THIS
Tel: Dumbarton +44 (0)1389 727900 DOCUMENT MAY COMPROMISE
Fax: Dumbarton +44 (0)1389 757405
THE WARRANTY OF INSTALLED
EQUIPMENT
THIS INSTRUCTION MANUAL AND THE INFORMATION CONTAINED WITHIN IT HAVE
BEEN FURNISHED FOR USE BY YOUR ORGANISATION ONLY AND FOR THE
PURPOSES CONSISTENT WITH THE TRANSACTION BETWEEN YOUR ORGANISATION
AND DIAMOND POWER. NO COPIES OF OR ANY DATA FROM THIS MANUAL SHALL BE
FURNISHED TO ANY THIRD PARTY WITHOUT THE WRITTEN AGREEMENT OF
DIAMOND POWER SPECIALTY LTD:
 +44 1389 727 900
 +44 1389 757 405 (fax)
 www.diamondpower.co.uk
 Diamond Power Speciality Ltd

Block 10
Vale of Leven Industrial Estate
Dumbarton,
Scotland. G82 3AD
ELECTRICAL SAFETY WARNING

Electrical Motors and Components are designed for operation in Industrial
Applications and in normal service there is a possible danger from rotating parts
and/or live terminals.
It is essential that motors and other electrical components are installed
or serviced by qualified personnel in order to avoid injury or death and/or
damage to euipment or installations.
If there are any safety concerns regarding any piece of electrical equipment,
please contact your nearest sales or service office for advice or assistance.
If there are any doubts about safety, do NOT install the unit or attempt to operate it.
We cannot be held responsible for damage as a result of installation or service by
unqualified personnel.
OPERATIONAL WARNING
When the blower is in operation, or during installation testing,
Steam, Hot Gases or Ash may, due to the nature of the process, be ejected in the
vicinity of the sootblower
Surfaces of the Wallbox, Poppet Valve and the Sootblower Lance can be very hot to
the touch during operation and PPE must be used at ALL times in the vicinity of the
Sootblower
Rev 1.0 Page 2 of 57

Table of Contents
1. CONTRACT IDENTIFICATION.....................................................................................................5
1.1 Contract Identification ................................................................................................................................ 5
2. GENERAL DESCRIPTION ..............................................................................................................6
2.1 Introduction................................................................................................................................................. 6
2.2 Thermoprobe Identification ........................................................................................................................ 6
2.3 Operating Cycle .......................................................................................................................................... 6
2.4 Application ................................................................................................................................................. 6
2.5 Safety Information ...................................................................................................................................... 7
2.6 Operation .................................................................................................................................................... 7
3. COMPONENT DESCRIPTION .......................................................................................................8
3.1 Mechanical .................................................................................................................................................. 8
3.2 Beam ........................................................................................................................................................... 8
3.3 Front Roller Support Assembly .................................................................................................................. 8
3.4 Wallbox Assemblies ................................................................................................................................... 9
3.5 Rear Support ............................................................................................................................................... 9
3.6 Carriage..................................................................................................................................................... 10
3.7 Electrical ................................................................................................................................................... 11
3.8 Limit Switches .......................................................................................................................................... 12
3.9 PositionTransmitter ................................................................................................................................... 13
3.10 Thermoprobe Tube – Air Cooled .............................................................................................................. 14
3.11 Probe Tube Cooling Air ............................................................................................................................ 15
4. INSTALLATION and COMMISSIONING INSTRUCTIONS ...................................................16
4.1 Stacking Thermoprobes ............................................................................................................................ 17
4.2 Thermoprobe Mounting ............................................................................................................................ 17
4.3 Manual Operation ..................................................................................................................................... 18
5. COMMISSIONING INSTRUCTIONS ..........................................................................................19
5.1 Cold Commissioning................................................................................................................................. 19
5.2 Hot commissioning ................................................................................................................................... 19
5.3 TP500-E Air Flow .................................................................................................................................... 20
5.4 Maintenance .............................................................................................................................................. 20
5.5 Maintenance Schedule .............................................................................................................................. 21
5.6 Standard Tool ........................................................................................................................................... 21
5.7 Optional Air Retract Tool ......................................................................................................................... 21
5.8 Lubrication ................................................................................................................................................ 22
5.9 Gear Rack ................................................................................................................................................. 22
5.10 Fault Finding ............................................................................................................................................. 23
6. MAINTENANCE WORKSHEETS ................................................................................................24
6.1 Removal and Re-Installation Procedure .................................................................................................... 24
6.2 Thermocouple Removal & Replacement .................................................................................................. 25
6.3 Wallbox Dismantling / Replacement – Negative Pressure ........................................................................ 30
6.4 Front Roller Assembly .............................................................................................................................. 31
6.5 Limit Switches – Renewal & Adjustment ................................................................................................. 32
7. PARTS IDENTIFICATION ............................................................................................................33
7.1 TP500-E Thermoprobe ............................................................................................................................. 34
7.2 Carriage Assembly .................................................................................................................................... 36
7.3 Carriage Roller Assembly ......................................................................................................................... 38
7.4 Roller Bracket Assembly .......................................................................................................................... 38
7.5 Roller Assembly........................................................................................................................................ 39
7.6 Control Assembly – (Typical) ................................................................................................................... 40
7.7 Electric Control Assembly – Limit Switch Arrangement – (Typical) ....................................................... 42
7.8 Control System - Proximity Switch ........................................................................................................... 44
7.9 Probe Tube Assembly – Air Cooled & Non Air Cooled - (Typical) ........................................................ 46
7.10 Air Inlet Manifold & Control Assembly ................................................................................................... 48
7.11 Air Inlet Manifold &Control Assembly - Parts - 398952-000A.............................................................. 49
7.12 Wallbox - Negative Pressure..................................................................................................................... 50
7.13 Rear Support Assembly ............................................................................................................................ 51

7.14 Auxiliary Support...................................................................................................................................... 52
8. RECOMMENDED SPARES LIST .................................................................................................57

9. ADDENDUM TO INSTRUCTIONS ...............................................................................................59
9.1 RISK ANALYSIS ..................................................................................................................................... 59
9.2 Mechanical Hazards .................................................................................................................................. 59
9.3 Electrical Hazards ..................................................................................................................................... 59
9.4 Thermal Hazards ....................................................................................................................................... 60
9.5 Errors of Installation ................................................................................................................................. 60
10. TECHNICAL DATA SHEETS........................................................................................................61
10.1 Thermoprobe Layout Sheets ..................................................................................................................... 61
10.2 Thermoprobe Wiring Diagram.................................................................................................................. 61
10.3 Probe Assembly ........................................................................................................................................ 61
10.4 Motor Data Sheet ...................................................................................................................................... 61

1. CONTRACT IDENTIFICATION
1.1 Contract Identification

Diamond Power
Contract No. N11836
Customer Doosan (DHIC)
End User Site Song Hau 1 Power Plant
Unit
Position No. Serial No. Tag No.
Number
--- B79361 1 P1HBK10CT001
---
--- B79362 1 P1HBK10CT002
--- B78963 2 P2HBK10CT001

---
--- B78964 2 P2HBK10CT002
Equipment Supplied
4 Off TP500-E
Customer Order No. 2016024277
Revisions
Rev Description Date By

1.0 First Issue – TP500-E Oct 2017 R.Smillie

2. GENERAL DESCRIPTION
2.1 Introduction
The TP500-E Thermoprobe is a mechanical device for positioning a thermocouple element in the furnace
gas stream for temperature monitoring. The thermocouple is mounted on the end of a probe tube which
traverses into and out of the gas stream.
The probe tube is attached to an electrically-driven travelling carriage which incorporates dual rack-and-
pinion drive.
The TP500-E permits continuous monitoring of the gas temperatures in the critical area just ahead of the
Reheater tubes at the exit of the furnace. Constant temperature control in this area reduces the danger of
heat damage to the tubes during boiler start-up before steam circulation is sufficient for cooling. The unit
can also be used to obtain gas temperatures which are used as an aid in controlling low-load operation.
2.2 Thermoprobe Identification

Each TP500-E in an installation is identified by a serial number and a position number, both of which are
marked on the nameplate.
2.3 Operating Cycle

The operating cycle begins with the unit in the retracted position. When power is applied to the electric
motor, the carriage moves forward by rack-and-pinion drive to project the probe tube into the boiler. When
the probe tube is inside the boiler, the carriage continues to project the thermocouple on the probe tube
into the boiler until it reaches its extreme forward travel. At this point, the carriage reverses its direction
and withdraws the probe tube from the boiler. The operating cycle is completed when the carriage returns
to its fully-retracted position.
A manual override, in the control system, allows the probe to be retracted at any point in its travel.
2.4 Application
The TP500-E is suitable for use as a start-up device in gas temperatures of up to 815°C and has a
maximum travel of 10.97m. When travel exceeds 7.6m the probe may sag due to the unsupported
section of the probe tube. This would cause the probe to deflect from its horizontal path. To ensure this
does not happen an additional support is added on the underside of the beam. To view a schematic of this
assembly please Refer to Section 7.13 for a diagram of the assembly.

2.5 Safety Information
Please ensure that all relevant personnel are made aware of the following safety information.
WARNING
THERMOPROBE
Keep clear and be aware of the following:-

 The Thermoprobe may be remotely operated and may start without warning.
 Various mechanical components of the Thermoprobe will move.
 Various surfaces of the Thermoprobe may become very hot.
 The Thermoprobe is supplied with live electrical supplies - ISOLATE ELSEWHERE.
 To STOP the Thermoprobe, switch the main electrical supply OFF, the thermoprobe
may re-start when supply is switched ON.
Do not operate the Thermoprobe locally unless permitted to do so.

Do not carry out maintenance until all voltage supplies are locked OFF.
2.6 Operation
The thermoprobe is controlled by limit switches mounted on the carriage and actuated by a series of
triggers mounted on the thermoprobe beam. When the carriage reaches the limit of its forward travel it
makes contact with the reverse trigger. This action reverses the drive motor and retracts the thermoprobe.
When the carriage reaches the cooling medium limit switch it will either carry on to its fully retracted
position or repeat the cycle again depending on the signal from the DCS panel. When the thermoprobe
completes its cycle the carriage makes contact with the reset trigger and stops the motor.
During the cycle, the thermoprobe‘s position is constantly monitored with a position transmitter. An
encoder counts the teeth of a pinion drive allowing the exact position of the probe to be known at any point
during the cycle.
Refer to Thermoprobe Wiring Diagram for a detailed layout of controls.
The Electrical wiring diagram is located at the end of the Instruction Manual

3. COMPONENT DESCRIPTION
3.1 Mechanical
The TP500-E Thermoprobe comprises a number of sub-assemblies as described in this section.
A comprehensive breakdown of the components is given in Parts Identification section.
3.2 Beam
The beam comprises a folded steel canopy onto which is welded, a front bulkhead plate.
The front bulkhead plate carries a roller assembly to support the probe tube. A rear support plate, bolted
to the front end, acts as a blanking plate for the canopy assembly. Four angle brackets, welded to the
canopy sides, support the carriage, via carriage rollers. Gear racks, attached to the upper angles, engage
with carriage pinions to provide travel.
The beam is supported at the front by a wallbox and wallsleeve. Bolts connect the wallbox to the front
support plate. Rear support is provided by a rear support assembly mounted to the installation structural
steelwork.
This method of suspension allows the thermoprobe to take the expansion and contraction of the boiler in
three planes.
Beam Assembly
Rack
Assembly Front
Bulkhead
Beam Roller Assembly

Rear Bulkhead Rear Support Lugs Wallbox
3.3 Front Roller Support Assembly

A roller assembly supports and guides the probe tube as it travels. Supportting lugs connect the wallbox to
the rear bulkhead, providing an air seal to the boiler.
Front Roller Support Assembly
Front Bulkhead Negative Pressure Wallbox

(Other Options Available)
Wallbox Support
Pin
Probe Tube
Support Roller Roller Mounting Bracket

3.4 Wallbox Assemblies
Wallbox – Negative Pressure
Seal Plate
To Boiler
Flange
Assembly
Spring Assembly Support Pin
3.5 Rear Support

The Thermoprobe is supported at the rear by a support assembly which is attached to the structural
steelwork. The screwed rods are assembled onto the structural steelwork to allow for vertical adjustment
as required. The supporting steelwork is not supplied by Diamond Power.
Adjustable Rear Support
Screwed Rods
Rear Support Bar
Support Lugs
Beam

3.6 Carriage
The carriage drives the probe into and out of the boiler. The assembly consists of a fabricated chassis
assembly, drive motor, and a gearbox.
Drive pinions, mounted onto the pinion shaft, engage with gear racks located on each side of the
thermoprobe beam and enable the carriage to travel along the beam. Support rollers are mounted onto
the pinion shaft.
Carriage Operation
Gearbox
Rack
Limit Switch Probe

Assembly
Drive Motor
Support Roller
Fabricated Chassis

3.7 Electrical
Electrical components on the thermoprobe comprise a drive motor, forward and rear limit switches and
terminal box. The wiring between the drive motor, limit switches and terminal box is part of Diamond
Power supply. The interconnecting wiring from the thermoprobe to the electric control panel is not part of
Diamond Power supply. To complete the electrical link up between the thermoprobe and the control panel
a wiring diagram is normally supplied by Diamond Power. (Refer to Technical Data Section)
When the drive motor is energised from the control panel it drives the carriage forward. As the carriage
approaches the limit of its forward travel, it activates the forward limit switch. This action reverses the drive
motor.
As the carriage approaches its fully retracted position, it activates the rear limit switch. This action stops
the drive motor.
Electric Drive Motor

The electric drive motor is a fixed-speed unit, mounted on the carriage.
Energy Chain
The Energy Chain cable arrangement transmits power from the terminal box located on the side of the
beam to the drive motor,limit and proximity switches. The cables are housed within a powerlink energy
chain arrangement, one end of which is mounted to the carriage with the other end fitted to a plate located
on the beam.
Energy Chain Operation
Terminal Box
Rear Support
Assembly
Tow Bracket
Carriage Limit Switch

Terminal Box

3.8 Limit Switches
Limit switches, mounted to the carriage chassis, control forward and reverse travel.
Limit Switch Operation
Limit Switch
Limit Switch Trip Plate
A typical limit switch assembly is shown below.

The limit switches are mounted on a support bracket attached to the carriage chassis.
A trip plate, mounted to a perforated rail, allows adjustment to be made by repositioning along the rail.
Limit Switch Assembly
Carriage
Mounting
Chassis
Mounting Rail
(Fixed to Beam
at Front)
Trip Plate
Front Operating
Limit Switch
Support Bracket
Rear Operating
Limit Switch
Mounting Rail
(Fixed to Beam at Rear)

3.9 PositionTransmitter
Motor
Gearbox
Trigger Wheel
(4 Tooth Pinion)
Probe
Tube
Gap Junction Box

0.1 – 1.0 mm
Pulse Count
Proximity
Switch
Rear Operating Limit Switch
Front Operating Limit Switch
A position transmitter proximity switch is mounted on the gearbox mounting bracket to provide an
accurate feedback on the position of the probe within the boiler.
A four toothed trigger wheel is attached to the gearbox extended shaft. The pulse count proximity switch
detects the movement of the teeth and the signal is fed to a counter unit which calculates the probe
position which can be displayed on an appropriate LCD.
Note. Refer to the Thermoprobe wiring diagram of Section 10. TECHNICAL DATA SHEETS.

3.10 Thermoprobe Tube – Air Cooled
Probe Tube
Air Outlets
Gland Adaptor
Thermocouple
Lead Wire
Tip Shield
Follower
Manifold
The probe tube consists of a thermocouple, stainless steel tube and manifold. It is mounted to the front of
the tube and is enclosed within a protective shield which is threaded for attachment to the tube. Leads
from the thermocouple run through the probe tube to a junction box located on the side of the fabricated
carriage chassis. The leads are ceramically insulated and enclosed within the steel tubing throughout their
length. The rear of the probe tube is sealed with a gland.
The cables from the junction box are fed to the beam mounted starter panel through the energy chain.
When air cooling is required, air cooling inlets are provided at the manifold. The cooling air flows through
the thermoprobe and escapes through nozzles situated near the probe tip.

3.11 Probe Tube Cooling Air
Air Hoses
Solenoid Valve
Air Pressure
Flow
Switch
Regulating
Valve
The system is controlled from main control system by signals.

In almost all cases, house air pressure will be adequate to properly cool the probe. In order to ensure that
the proper amount of cooling air is supplied, the minimum pressure at the inlet to the motor operated shut
off valve (Solenoid) must be maintained.
As the probe is energised the probe moves the tube/tip into the boiler, the cooling medium limit switch is
tripped and sends a signal to the control. Control should now send a signal to the solenoid valve to open
the air line. This allows cooling air to flow through the probe tube to cool the probe during use.
A tapping from the inlet air is fed to an Air Pressure Switch which has been set to the minimum air cooling
pressure advised as being acceptable. Please refer to contract Thermoporbe layout sheet for pressure
switch set point. A period of between 5 to 10 secs is allowed in order to average out any fluctuations in
pressure. After this point, if the air pressure switch reads a pressure limit, equal to or above the minimum
set point, the probe is allowed to continue its travel into the boiler. If the minimum set point pressure has
not been reached a signal should be sent to control to retract the probe to its fully retracted position.
At the end of thermoprobe travel, the Front Limit Switch will be tripped and this will send a signal to control
to stop the travel and reverse the probe. Once again the cooling medium limit switch will be tripped and a
signal will be sent to control to operate the solenoid valve and stop the air flow. The probe will continue in
reverse until the Rear limit switch has been tripped sending a signal to control to switch off power to the
motor.
The air pressure is set at installation by manually moving the probe into the boiler (Refer to Manual
Operation in Section 4.3). When the cooling medium limit switch has been tripped, air will pass into the
probe tube. The amount of air used can be adjusted by turning the flow regulating valve mounted to the
solenoid. After seting the pressure, re-check after a few operations and asjust if necessary.

4. INSTALLATION and COMMISSIONING INSTRUCTIONS
General
Installation drawings are supplied with each set of thermoprobes. These drawings show the location of the
thermoprobe in the installation, overall dimensions, method of mounting, extent of Diamond Power
equipment supplied, and connections to be made. These drawings can be found in the Technical Data
Section of this manual.
Handling Packed Equipment
Thermoprobes which are packed in boxes or crates must be handled by slinging the boxes, using two
slings. Boxes and crates supplied are specially reinforced for the purpose.
Receipt at Site
On receipt at site, it is recommended that the thermoprobe should be removed from its crate or boxes, all
polythene wrappings removed, and the equipment stored in a dry building where temperature and
humidity are controlled to prevent condensation. Thermoprobes should be stored the correct way up and
not on their sides. Inspect for damage from shipment or storage.
During storage, thermoprobes should be inspected at monthly intervals.
Lifting the Thermoprobe
Thermoprobes should only be moved by slinging from the four lifting lugs provided on the top of the beam.
Use of a two-point sling or any other method is not permitted.
Caution: Do not use a sling around the beam or the protruding probe tube, as this may cause
damage and subsequent malfunctioning.
Typical Slinging Arrangement.
Lifting in unsupported area danger.
Do NOT sling around beam

as damage to the rack &
track drive mechanism can
occur.

4.1 Stacking Thermoprobes
Stacking Thermoprobes
Each thermoprobe should be placed on timber battens of sufficient thickness to keep all parts of the
equipment well clear of the ground. The battens should be placed under the main beams at approximately
one third of the length in from each end. Equipment may be stacked up to three units high, in double rows,
by placing timber battens across each pair directly above the ground support battens. To allow for
inspection, electrical boxes should face outwards.
4.2 Thermoprobe Mounting

Location
Each thermoprobe is identified on the appropriate installation drawing by a serial number; this number is
marked on the thermoprobe nameplate. Care must be taken to ensure that each thermoprobe is installed
in its correct location.
The thermoprobe is mounted on the boiler at two points. At the front mounting point, the wallbox is welded
to a boiler wall sleeve, normally provided by the customer. A rear support on the thermoprobe is attached
to the installation supporting steelwork.
For full mounting details, refer to Layout Sheets in Technical Data Section.
Ensure that the wallsleeve has been welded to the boiler wall.
Assemble the rear support screwed arrangements to the supporting steelwork.
Remove the wallbox from the thermoprobe. Position and weld the wallbox to the wallsleeve.
Note:
Ensure that the wallbox has been correctly orientated and that the inlet hole on the positive pressure
wallbox is as per layout drawing.
Lift the thermoprobe into position using the lifting lugs provided on top of the beam.
Fit the thermoprobe to the wallbox, locating the mounting pins and spacers correctly.
Connect the sealing air pipework to the wallbox. (Positive pressure applications only)
The cooling air supply must be connected to the hose fitting on the stationary manifold assembly, when
applicable.
Observe the alignment of the beam arrangement: check for any bends, twists or other distortions.
Make the power and control connections to the thermoprobe terminal box; ensure that there are no loose
terminals or wiring. Leave the thermoprobe ready for commissioning.
Rear Support Assembly
Rear Support Bar Screwed Rod
Top Cover Plate
Cotter Pin
Washer
Note:
Fit guards (When Applicable) after commissioning. (Refer to installation drawing - Technical Data Section)
Fill carriage with appropriate amount of oil before proceeding, refer to lubrication section.
Electrical Connections
Make the power and control connections. Refer to wiring diagram and Control Systems Interconnection
diagram.
The motor current on the spec sheet is approximate and will depend upon many factors
(voltage, installation, tightness of wallbox, packing and gland tightness etc.)
If the current varies greatly, address these areas.

4.3 Manual Operation
Warning: Before attempting to use the unit in Manual Mode, ensure that the Electrical Supply has
been disconnected.
During maintenance, or in an emergency, the thermoprobe carriage can be operated by turning the
extended shaft on the gearbox with an air ratchet wrench fitted with an Hexagonal Bit to the winder
adaptor. In a right or left hand blower, rotate the socket in a counter clockwise direction to reverse the
carriage towards the normally fully-retracted position.
Under no circumstances should an impact driver be used on the adapter.
Alternatively, an emergency retract air tool, consisting of an air motor with a motor mounting and shaft
coupling can be attached for speedier retraction. Refer to D.P.S.L for further information.
Manual Operation
Winder Adaptor
Air Wrench
Hexagonal Bit
Warning:
It is essential to keep the cooling air supply ‘ON’ to cool the probe tube until it is retracted.
The thermoprobe must always be returned to the fully retracted position after manual operation to
reset the limit switches.

5. COMMISSIONING INSTRUCTIONS
Inspection
Check that the thermoprobe is complete as specified in the packing list supplied with the unit. It is
important to ensure that the correct thermoprobe has been installed; this can be checked by reference to
the serial number typed on the nameplate. Prior to operating the thermoprobe for the first time, an
inspection should be made to ensure that it has been properly installed. Ensure that all connections
(electrical or air, where appropriate) have been made, and that it has not sustained any damage since
installation.
5.1 Cold Commissioning
Functional checks should be made before the boiler comes on-load, (i.e. without power) to ensure that the
thermoprobe mechanism is operating correctly.
Ensure that all lubrication has been carried out before any travel is permitted.
Check that the mounting and connecting bolts are secure and that all connections have been properly
made as specified in the installation section of the manual. Check that parts are free to move.
Check that there are no obstructions on the rack or track.
Check the rack and pinions drive mechanism is properly engaged and apply a light coating of grease.
Visually inspect the motor cable and thermocouple lead wire for any sign of damage during installation
and tighten all terminal connections at the junction and starter boxes.
Check the actuating arms of the limit switches for positive mechanical operation and freedom of
movement. The thermoprobe should initially be operated manually to check for freedom of movement and
correct functioning of the mechanism.
Manual Operation
Pre-operational Checks with Power On
Move the carriage forward manually until the carriage clears the rear limit switch.
Switch ON the power supply – (refer to the control panel instruction manual if in doubt.)
Check the motor rotation – refer to the Control Panel Instruction Manual.
When the panel is switched on, the thermoprobe moves forward when the forward contactor is energised.
Similarly, when the thermoprobe is set to reverse, the reverse contactor should be energised.
During forward travel, trip the forward limit switch manually and check that the carriage retracts.
Ensure that the carriage stops when the carriage trips the rear limit switch.
Check that the pulse count proximity switch detects the movement of the grearbox trigger wheel.
Press the local 'START' push-button, if fitted, and allow the thermoprobe to run through a complete cycle.
Observe the current as it operates and compare it with the motor rating plate figure to determine if
overloading is occurring. Rectify if necessary.
Reverse the carriage travel and check the following:
Check that the carriage operates the rear limit switch.
Check the power supply to the thermoprobe and that all cables are securely located within the energy
chain.
5.2 Hot commissioning
Hot commissioning is carried out with the boiler on full load and the thermoprobe has been mounted
correctly with all cold commissioning checks having been carried out.
Operate the thermoprobe manually and check that all of the mechanisms function correctly.
Operate the thermoprobe from the local push-button (where fitted) to check the direction of travel and the
operation of the limit switches; repeat from the remote control panel.
Operate the thermoprobe with the cooling air 'ON'. Check for leaks and rectify as necessary.
Set the Wallbox Sealing Pressure, where applicable. This can only be carried out with the boiler on-load.
The thermoprobe should be operated through several complete cycles, with the cooling air on, to check
that it is functioning correctly before finally putting it into service.

5.3 TP500-E Air Flow
The Diamond Thermoprobe is designed principally to give dependable flue gas monitoring at the
Superheater/reheater inlet during boiler start up to avoid tube metal overheating under no flow
conditions. For this duty it is normally required to monitor temperatures up to 649oC (1200oF) only. The
probe is not intended for monitoring furnace gas outlet temperatures at partial or full load and its use is
not recommended above 816oC (1500oF) as readings become unreliable due to slag formation on the
thermocouple tip. Cooling flows required are dependent on gas temperatures and probe lengths and are,
therefore, considered on an individual basis.
For a Probe with a travel up to 8,763 mm the Probe is suitable for inserting in a gas temperature up to
543oC (1010oF) without cooling air. When using cooling air supplied at 0.156 NM 3/sec (350 scfm) at a
pressure of 3.10 bar g (45 psig), the Probe is suitable for inserting in a maximum gas temperature of
816oC (1500oF).
5.4 Maintenance
Operational Checks Periodic Inspection
The thermoprobe should be inspected periodically to ensure that:
All mechanisms are functioning correctly.
All moving parts on the carriage are adequately lubricated with recommended lubricants.
Thermocouple tip and probe tube are in good condition.
Limit switches, proximity switch and electric motor are operating correctly.
Power and control cable run smoothly within the energy chain arrangement during forward and reverse
travel of the carriage.
The front roller is adequately lubricated.
The frequency of inspection will depend on operating conditions, but should be at least once a month.
Annual Maintenance
The thermoprobe should be inspected annually for deterioration of all critical parts; these should be
renewed, where necessary. Mechanisms should be checked and adjusted, where necessary.
Critical parts include, but are not limited to, the following:
Rack and pinion.
Support Rollers.
Limit and proximity Switches.
Manual Operation for Setup or System Check
All thermoprobes can be operated manually by attaching a ratchet wrench to the winder adapter on the
extended drive gearbox shaft. Refer to section 4.3.
If a fault develops with a set of thermoprobes during automatic sequential operation, the thermoprobes
should retract automatically. If they fail to do so for any reason, such as power failure, motor stalled, etc.,
immediate action must be taken to withdraw the thermoprobes involved.

5.5 Maintenance Schedule
General
Thermoprobe controls should be arranged to protect the plant and the thermoprobe from damage in the
event of a fault developing. The Maintenance Schedule is designed to maximise thermoprobe availability.
Periodic Inspection
Frequency of this inspection will depend on operating conditions, but should not be less than once per
month. Points to be checked are;
All mechanisms are functioning properly. Do not lubricate excessively as this attracts dirt.
Routine Maintenance
Routine maintenance should be carried out annually, with the thermoprobe in situ and with all services
connected, but isolated as appropriate. Critical parts, which should be examined in more detail during
routine maintenance, are as follows; Carriage - Check for overheating and noisy running.
Limit / Proximity Switches - Check for correct operation.
Motor - Check for overheating and freedom of movement.
Major Overhaul
The thermoprobe should be inspected after a period of long usage for possible renewal of all wearing
parts. If necessary, as a preliminary to this operation, the thermoprobe should be run and checked for any
malfunctioning. The procedure for examining critical parts is similar to that given for Routine Maintenance.
5.6 Standard Tool

Certain Jobs described in the Maintenance Section can best be accomplished using the Standard,
special-purpose tool detailed below.
Standard Manul Turning Tool – Delivered with Each Thermoprobe
Adapter Tool
Fit to Air Drill for Manual

Adjustment of Travel for
test or Manual Removal of
Probe
5.7 Optional Air Retract Tool

Available to Purchase Separately
Hexagonal Bit
Air Drill Purchased Separately
Purchased Separately (Part No. 399222-000A)
(Part No. 909305-8910)
Adapter Tool
(Supplied with
Thermoprobe)

5.8 Lubrication
General Lubrication
The gearbox on the carriage is a sealed for life unit and if necessary should be replaced and not
refurbished.
Bearing Shaft (Front Support Roller)
The bearing shaft is fitted with “sealed for life” bearings and require no further lubrication. When worn they
should be replaced.
Bolt Heads and Threads
If any bolts are temporaily removed from the thermoprobe, the heads and threads should be coated with
an anti-seize compound such as Molykote G or Thread-Gard before replacement.
Rack and Pinion Drive
Apply a light coating of oil on a regular basis. No NOT overload as this can attract dirt which could have a
detrimental effect on the carriage movement.
5.9 Gear Rack

Gear rack grease, such as Mobilgrease Special (now also known as Mobilgrease XHP 222) can be
applied to the sootblower rack. However,this is a very tacky chassis grease which will work well but will
attract ash and dust. This can be a real problem at some sites and alternatives such as dry film lubricants
should be used where atmosphere pollution is an issue. Apply fresh grease every six months or 500
cycles.
In situations where the atmosphere contains a significant amount of ash or dust, Mobilgrease Special
should be replaced with a synthetic oil such as Royal Purple ™
http://www.royalpurple.co.uk/royal-purple-industrial.html
“Synerlec® is Royal Purple's proprietary, lubricant additive technology that strengthens the oil film to
provide extra protection and performance.
Royal Purple continuously protects because Synerlec® continuously adheres to metal parts — even after
shutdown. The thin film of oil that remains after shutdown preserves parts and provides instant lubrication
at start-up until a full fluid oil film can be established.”
Royale Purple runs clean and does not attract dirt.
Apply fresh Royal Purple ™ every month or 100 cycles.

5.10 Fault Finding
Symptom Possible Cause Remedy
Thermoprobe fails No power: Check power supply.
to start. Overload tripped. Check continuity.
Motor fault. Test and rectify circuit.
One power line open: Re-establish continuity.
Overload relay trip due to motor single
phasing.
Contactor fault
Thermoprobe jams Drive motor overloaded. Check the orientation of wallbox

or fails to travel. Dirt or swarf in the wallbox. on the boiler wall.
Pinion is jamming on the rack. Adjust the mounting angle of the
Pipework incorrectly supported stressing the thermoprobe.
thermoprobe. Clean the wallbox using
Carriage Fault compressed air.
Inspect the rack for alignment
and clean the pinion teeth.
Thermoprobe fails Limit switch or Proximity Switch fault. Check the trip lever or actuator
to stop. operates the switch.
Renew the switch if necessary.
Thermprobe Jams Front Support Roller incorrectly aligned. Re-align.

or fails to travel. Probe Tube fouling in wallbox. Check orientation of wallbox on
boiler wall.
Dirt, Swarf or other debris in wallbox. Clean wallbox using compressed
air.
Probe tube fouling on furnace internals. Adjust mounting angle of probe
tube.
Pinion jamming on rack. Inspect rack for mis-alignment or
contamination.
Probe tube Auxiliary support (If fitted) out of alignment. Loosen cap screws and re-
tracking position auxiliary support.
incorrectly.
Motor taking Debris in Wallbox. Investigate wallbox condition.

excessive current. Wallbox Seal Plates tight. Adjust if required.
Support Rollers misaligned. Re-align rollers.
Is high current throughout the travel in forward Check for tight spots on the rack.
and reverse.
Control Room Damaged Thermocouple. Replace thermocouple.

Panel indicator or Defective instrumentation wiring.
thermocouple does Open circuit in wiring. Check continuity of circuits.
not register.
Position transmitter Gap between switch and trigger wheel pinion Re-set gap to 0.1 – 1.0mm.
does not register. incorrect.
Limit/proximity switch defective. Fit new switch.
Wiring fault. Check wiring.

6. MAINTENANCE WORKSHEETS
6.1 Removal and Re-Installation Procedure
CAUTION:-When lifting or lowering the thermoprobe, it must only be moved by slinging from the four
lifting lugs provided on the top of the beam. The use of a two-point sling or fork lift truck is likely to cause
damage and subsequent malfunction.
Removal
Ensure that the thermoprobe is in the fully-retracted position.
Disconnect the thermoprobe from the power supply.
Fit the lifting equipment to the four lifting lugs provided on top of the beam.
Disconnect the electrical cables as necessary to permit removal of the thermoprobe.
Take the weight of the thermoprobe.
At the rear support bracket, disconnect from site fabrication.
At the front support assembly, remove the two pins,spacer,washers and cotter pins between the wallbox
and front bulkhead plate.
Disconnect the wallbox.
NOTE: Before lowering, the thermoprobe must be pulled away from the wailbox to prevent damage to the
probe and tip.
Carefully lower the thermoprobe onto wooden battens of sufficient thickness to keep all parts of the
equipment well clear of the support structure on which the unit is placed.
Re-installation
Remove any protective coverings from the thermoprobe.
Carry out a detailed inspection of the complete thermoprobe for any signs of damage.
Fit the lifting equipment to the four lifting lugs provided on top of the beam.
Carefully lift the thermoprobe into position.
NOTE: Ensure that the carriage is fully retracted before commencing re-installation.
At the front support assembly, replace the pins, spacer, washer and cotter pins which secure the wallbox
to front bulkhead plate.
At the rear support bracket, re-connect the rear support assembly to the site mounting fabrication.
Reconnect the electrical cables.
Disconnect and remove all lifting equipment.
Re-connect the power supply, and complete the post-maintenance checks.

6.2 Thermocouple Removal & Replacement
NOTE
Before renewing a thermocouple, the following checks should be made to ensure that a replacement is
necessary.
Check all wiring for continuity and make certain that all electrical connections are tight.
With the boiler operating, run the probe tube forward approximately 300mm to place the thermocouple tip
in a higher gas temperature.
Check that the temperature readout device indicates an increase in temperature.
If no change in temperature is indicated, disconnect the read-out device and monitor the thermocouple
signal with a suitable test instrument to ensure that the read-out device is operating correctly
NOTE
An alternative method of testing is to turn on the aspirating air, if fitted, with the probe tube fully retracted.
If the thermocouple is operating correctly, the temperature read-out device should indicate a decrease in
temperature
Thermoprobe Removal
Retract the probe to the rear limit switch and Isolate the power supply to the main Control Box.
Warning:
It is essential to keep the cooling air supply ‘ON’ to cool the probe tube until it is retracted.
Before removal of the probe, the normal stop block at the end of the rack, on each side of the beam, must
be removed. Do NOT remove the rear stop block. Remove the two hexagonal bolt and washer assemblys
on each block to allow the carriage and thermoprobe assembly to be retracted.
Rear Stop Block
Rack
Normal Stop Block
Stop Block Mounting Screws Beam
Manual Operation

Winder Adaptor
Wrench Air Retract Tool

Control Box
Retract Button
Gearbox Extended Shaft
Turn the extended shaft on the gearbox with a ratchet wrench fitted to the winder adaptor. In a right or left
hand blower, rotate the socket in a counter clockwise direction to reverse the carriage towards the
normally fully-retracted position.
Under no circumstances should an impact driver be used on the adapter.
Turn off the air supply to the thermoprobe.
Isolate the Thermoprobe from the power supply.
Remove the four terminal box cover plate screws and disconnect the thermocouple wires from the
terminal box mounted to the carriage assembly. Disconnect the tails of the thermocouple from the terminal
box. Remove the cable and packing gland.
Thermocouple Disconnection
Terminal Box Cover Screws

Carriage
Probe Tube
Manifold Terminal Box
Thermocouple Wires
Thermocouple Manifold

Thermoprobe
Manifold
Tie Bar
Cable &
Packing Gland
Disconnect the air hoses from the elbow connection leading from the thermoprobe manifold.
Air Hose Elbow

Connection
Position support blocks at the probe tube near the carriage and at the front support bracket; rest the
blocks on the beam flange. Remove the four hexagonal screws and lockwashers which secure the
manifold to the carriage and rest the probe on the tie bars. Ensure that the probe tube does not drop and
damage the manifold.
Manifold Mounting
Screws

Slide the probe tube back until the thermocouple tip protective shield clears the wallbox.
Ensure that the blocks at the front support bracket support the tube and do not damage the tip as the tube
is pulled off the rollers.
Remove the thermocouple tip shield at the front of the probe.
Remove the follower from the recess. Remove the sealant, noting that a new sealant must be added at re-
assembly.
Withdraw the faulty thermocouple from the probe tube through the manifold.
Push the new thermocouple into the probe tube until the end protrudes about 45mm from the tube end.
Air Inlet
Probe Tip
Shield
Packing
Follower
Sealant
Thermocouple
Thermocouple
Probe Tube
Thermocouple
Tip Shield
Thermocouple
Tip Shield
Insert new sealant and follower.

Grease the threads of the protective tip shield with Molykote G or equivalent, and replace the shield;
tighten the shield firmly.
Lift and support the probe tube and carefully push it over the front support rollers and into the wallbox.
Replace the four hexagonal bolts and lockwashers which secure the manifold to the carriage.
Connect the tails of the thermocouple and the thermocouple lead wires to the terminals in the junction
box. Replace the packing at the rear and secure the junction and terminal box covers.
Remove the blocks used to support the probe tube.
Test the new thermocouple installation.
The thermoprobe must always be returned to the normal retracted position after manual operation
to reset the limit switches.

Thermocouple Replacement
Carriage
Fabrication
Probe
Tube
Terminal Box
Packing Gland
Manifold Mounting Bolts
Manifold
Thermoprobe & Wallbox
Support Roller

6.3 Wallbox Dismantling / Replacement – Negative Pressure
Wallbox Removal:
Isolate the thermoprobe from the power supply to prevent automatic operation of the unit.
Shut off air cooling supply.
Ensure that the carriage is in the fully-retracted position.
Attach a sling to the front & rear support lugs of the thermoprobe.
Remove the probe tube. – If raised rollers, remove the seal plate first.
Remove the split pins which connect the thermoprobe to the wallbox.
Disconnect rear end from supports.
Support rear end.
Carefully swing the thermoprobe away from the wallbox.
Remove the four nuts, springs and washers which secure the seal plate to the wallbox Remove the seal
plate. Renew any items if necessary.
Wallbox Dismantling - Negative Pressure
Front Bulkhead Spring/Nut/

Washer
Washer
Wallbox / Wallsleeve
Mounted to This
Face
Probe Tube
Seal Plate
Split Pin
Grease Nipple Front Roller Assembly
Wallbox Renewal:
Remove the weld between the wallbox and the wall sleeve.
Position and weld a replacement wallbox to the wall sleeve.
Replace the seal plate, washers, springs, and nuts.
Re-install the thermoprobe in the reverse order to that given for dismantling.

6.4 Front Roller Assembly
Bearings
Washer
Set Screw Hex Bolts/Washers
Roller Bracket Support Lug
Assembly
Isolate the Thermoprobe from the power supply.

Visually inspect the front support structure for signs of damage, distortion, corrosion or deterioration.
renew any defective items.
Dismantling the fixed Roller

Remove the two hexagonal bolts, nuts and washers which secure the roller bracket arrg't to the front
plate. Remove the complete roller assembly with bracket from the front plate.
Loosen the set screw which retains the roller shaft.
Carefully tap out the shaft and separate it from the lugs washers and roller assembly.
Cleaning and Inspection
Thoroughly clean all components using a lint-free cloth and solvent.

Inspect the components for signs of damage, distortion or excessive wear, paying particular attention to
the bearing surfaces.
Check the lubrication supply to the shaft via the lubrication fitting.
NOTE
It is recommended that ball bearings and bearing seals be renewed. Where doubt exists as to
serviceability, new items should be fitted.
Reassemble in the reverse order to that given for removal.

Test run the Thermoprobe manually (POWER OFF) and under normal power control (POWER ON) to
monitor the travel of the probe tube over the fixed front roller.

6.5 Limit Switches – Renewal & Adjustment
Renewal
Isolate the thermoprobe from the power supply.
Shut off the blowing medium supply.
Unscrew the cable gland and connecting cable from the faulty limit switch, noting the correct wire
termination points.
Remove the two mounting screws and lockwashers which secure the faulty limit switch to the limit switch
bracket. Remove the limit switch from the bracket.
Select a new limit switch and install it in the reverse order to that given for removal; ensure that the wires
are fitted to the same termination points.
Rear Limit Switch
Fixing Screws
Roller
Cable Gland
Limit Switch
Limit Switch Bracket Assembly
Adjusting
Screw
Adjustment Procedure
Check that the contact roller engages correctly with the carriage. The angular position of the roller crank
can be altered by loosening the adjustment screw.
The limit switch position can also be adjusted by slackening the fixing screws on the mounting rail or limit
switch plate and sliding the whole assembly in the direction of the adjustment required.
Re-tighten after adjustment.
Operate the thermoprobe manually to check that the limit switches operate correctly when tripped by the
trip plate assembly.
Turn on the blowing medium supply.
Reconnect the power supply and test run the thermoprobe.
Note:
The first and second limit switches are used to set the fully inserted and fully retracted positions of the
thermoprobe.
A third limit swith is used when cooling air is used. A signal from this limit switch will send a signal to the
control system as it is tripped during insertion into the boiler. The transmitted signal will trip the cooling air
input valve allowing the probe to be cooled as it is in the boiler.Refer to Electric Control Assembly Drawing
at the end of the Instruction Manual.

7. PARTS IDENTIFICATION
The correct part names for spares ordering can be identified by referring to the following assemblies.
Please quote:-
 DPSL Contract Number.
 Thermoprobe Serial Number.
 Thermoprobe Position Number.
 Figure Number, Item Number and Page Number from this manual.
A recommended spares list can be supplied on request.
Contact D.P.S.L. Spares Department

Telephone +44 (0) 1389 727900
Fax +44 (0) 1389 757405
Standard Sub Assemblies Drawing No.

Main Assembly - Overview *************
Carriage Assembly (R=RH & L = LH) 398951-R000
Carriage Roller Assembly 398951-0049
Roller Bracket Assembly 397022-000A
Roller Assembly (Roller Bracket Assembly) 394347-4035
Control Assembly – Typical Assembly 399009-B300
Electric Control Assembly - Wiring Diagram N11836-4-618
Energy Chain Assembly 399010-0061
Probe Tube Assembly N1183614-C023
Air Inlet Manifold Assembly 398952-000A
Wallbox Assembly 397142-4A10
Seal Air Assembly N/A
Rear Support Assembly 397736-000A
Auxiliary Support 399259-000A
Drive Motor N11836-861
Guard Assembly N/A

7.1 TP500-E Thermoprobe
14
12
8 10
13
3
1 11
19 9
4-5
21
1
6
15

TP500-E Thermoprobe – Parts
Item Description Qty Part Number
1 Beam Assembly 1 N1183614-C022
2 Top Cover 1 395421-1128
3 Carriage Assembly 1 398951-R000
4 Roller Assembly 1 394347-4035
5 Roller Bracket Assembly 1 397022-000A
6 Probe Assembly 1 N1183614-C023
7 Control Assembly 1 399009-B300
8 Energy Chain Assembly 1 399010-0061
9 Electrical Parts 1 N11836-618
10 Motor 1 N11836-861
11 Wallbox 1 397142-4A10
12 Rear Support Assembly 1 397736-000A
13 Stop Block 4 397976-010F
14 Track Removable Section 2 398224-010A
15 Tie Bar 4 397981-010A
16 Piping Assembly 1 N/A
17 Nameplate – (Not Shown) 1 N1183612-C138
18 Ø4.8 x 8mm Pop-Rivet 4 864536-8903
19 Diamond Emblem 2 398704-010A
20 Lifting Caution Tag – (Not Shown) 1 399321-010A
21 Carriage Alignment Sticker 2 396955-010A
#Item 18 (Pop Rivets) are not shown on scheme but are used to mount the Nameplate – Item 17.

7.2 Carriage Assembly
11
Motor 21-23
1 24
25
20-21-22
2
10
9 25
3 5
26
7
18-19
6
16 4
13 12 14
15
8 8
17
13
9
7
20-21-22 2

TP500-E – Carriage Assembly - Parts - 398951-R000

1 Spaggiari SW063 Gearbox and Spacers 1 398234-000A
2 Carriage Chassis, TP500 1 398211-000A
3 Pinion Shaft 1 398213-010B
4 Collar, Pinion Shaft 1 398214-010B
5 Mounting Foot, TP500 1 398209-010A
6 Ball Bearing, 6208-2RS1 2 901110-0049
7 12T Pinion 2 324188-1121
8 Spacer, Roller 2 324128-1124
10 Junction Box Assembly 1 398217-000A
11 Gasket B5-80 Frame Motor 1 343831-1130
12 8x7x90 Key 1 862401-8905
13 Key, 1/4" Sq. x 1.625" Lg. 2 306037-7110
14 Internal Retaining Ring, 80 x 2.5, N5000-315 4 907920-0066
15 External Retaining Ring, 40x1.75 4 907920-0080
16 M10 x 1.5 x 10 Lg. Hex. Soc. Hd. Cup Pt. Grub Screw 2 876006-4410
17 External Circlip,63/64"x0.042", 5100-98 2 907920-0010
18 M8 Lockwasher, Split Type 4 879016-4000
19 M8 x 1.25 x 25 Lg. Hex. Hd. Screw 4 875005-4025
20 M10 Washer, Form-A 2 879006-4400
22 M10 x 1.5 - 25 Lg. Hex. Hd. Screw 2 875005-4425
23 M10 x 1.5 Hex. Nut 4 873015-4400
24 M10 x 1.5 - 35 Lg. Hex. Hd. Screw 4 875005-4433
25 Side Reaction Button 4 398890-010A
26 M6 x 1.0 x 30 Lg. Hex. Soc. Hd. Screw 4 875007-3530

7.3 Carriage Roller Assembly
14 14
13
7
17
8
9 15 6
Carriage Roller Assembly – Parts - 398951-R000 – (Part of Carriage Assembly)

6 Ball Bearing, 6208-2RS1 2 901110-0049
7 12T Pinion 2 324188-1121
8 Spacer, Roller 2 324128-1124
13 Key, 1/4" Sq. x 1.625" Lg. 2 306037-7110
14 Internal Retaining Ring, 80 x 2.5, N5000-315 4 907920-0066
15 External Retaining Ring, 40x1.75 4 907920-0080
17 External Circlip,63/64"x0.042", 5100-98 2 907920-0010
7.4 Roller Bracket Assembly

2
2
5
1
4
3
3
Roller Bracket Assembly (Front Support) – Parts – 397022-000A

1 Backplate 1 397023-010A
2 Lug, Roller Support 2 RF09020MS
3 Hex. Hd. Screw 2 871014-5242
4 Hex. Nut 2 873015-5200
5 Washer 2 879006-5200
6 Set Screw 1 876009-4416

7.5 Roller Assembly
3
1-4-7 8 2
6 5
Roller Assembly (Front Support) – Parts – 394347-4035 – (Sealed for Life Bearings)
1 Roller – 3 ½” Lance 1 319546-1128
2 Ball Bearing 2 901110-8924
3 Washer 2 901402-0001
4 Roller – 2 3/8” Lance 1 N/A
5 Shaft Roller 1 394056-2121
6 Grease Nipple 1 N/A
7 Roller 5” Guide Tube – (Not Used on TP500-E) 1 N/A
8 Hex Soc. Hd. Screw 1 876009-4416

7.6 Control Assembly – (Typical)
2-3 34
11-12
5-6
30
10 4
8
9
24-29-
31-33
28
13-14-15
7
2-11
21-22
19
24-25 4 LIMIT SWITCH ASSEMBLY

27-28
19
21-23
24-25
21-22 30
19
28
32
2 LIMIT SWITCH ASSEMBLY
24-29-31-33
17
PROXIMITY SWITCH
ASSEMBLY
16
18

Control Assembly - Parts – 399009-B300
(For Contract Specific Layout Refer to Drawing at End of Instruction Manual)
1 40 x 30 Beta Duct, 175mm Lg. 1 849575-9194
3 M6 x 1.0 x 10 Lg. Slotted Pan Hd. Screw 2 875611-3510
4 Tow Bracket, TP500 1 398954-010A
5 M8 Washer, Form-C 6 879006-4002
8 M8 Washer, Form-A 2 879006-4000
9 Energy Chain Mounting Block 2 398976-010A
10 Energy Chain Mounting Plate 1 398976-010B
12 M8 x1.25 x 16 Lg. Hex. Soc. Hd. Screw 4 875007-4016
13 M10 Washer, Form-C 2 879006-4402
15 M10 x 1.5 - 20 Lg. Hex. Hd. Screw 2 875005-4420
16 Proximity Switch Mounting Bracket, TP500-E 1 398248-010A
17 Trigger Wheel, Position Indicator 1 398247-010B
18 M5 x 0.8 x 5 Lg. Hex. Soc. Hd. Cup Pt. Grub Screw 1 876006-3205
19 Double Limit Switch Bracket 1 398383-010A
20 Single Limit Switch Bracket 1 398383-010B
22 M6 x 1.0 x 16 Lg. Hex. Hd. Screw - 875005-3516
23 M6 x 1.0 x 80 Lg. Hex. Hd. Bolt 12 871014-3544
25 M5 x 0.8 x 40 Lg. Slotted Pan Hd. Screw - 875608-3236
26 Spacer, 40mm - 849571-9188
27 Spacer, 20mm 3 849571-9027
28 CP2020 Rail, 300mm Lg. 12 398494-A0300
29 CP2020 Rail Twin Face Nut 6 398360-010B
30 M5 x 0.8 x 20 Lg. Hex. Soc. Hd. CSK Screw 6 875004-3220
31 M5 Plain Washer, Form 'C' 1 879006-3202
32 Air Trip Plate 6 398899-010A
33 M5 x 0.8 - 16 Lg. Hex. Soc. Hd. Screw 8 875007-3216
34 Trip Plate 2 398898-010A
Notes.
Refer to the wiring diagram for details of cables, glands, terminals, proximity switch and front and rear limit
switches. (LSF & LSR)
Cables are routed through the energy chain to the main terminal box mounted on the beam shell. Refer to
the wiring diagram to for connections.
The proximity switch mounting bracket is attached using two of the gearbox mounting foot screws, The
bracket is slotted so that the screws need only be slackened back to allow fitment.
Ensure that the set gap between the proximity switch and the trigger is set correctlt to 0.1 – 1.0mm.
Limit switches are shown with their respective operating levers in the operated position.
Adjust lever angles and trigger positions to achieve the correct switching points.
If possible arrange the carriage start and stop positions to coincide with a scallop on the proximity
switch trigger wheel.
Ensure that all cables are clear of of the trigger wheel and extended worm shaft. The latter is used to
manually move the carriage.
For details not shown in diagram above, refer to section 6.7 for clarification.

7.7 Electric Control Assembly – Limit Switch Arrangement – (Typical)
20 21-22 19
24-25 24-25 21-22
Single Switch Double Switch
19 21-22 24-25 19
21
22
24-25
19
21-23
20
26
Triple Switch Quadruple Switch 27
32
28
30
24-29-31-33
Limit Switch Trip Assembly
30
28
24-29-31-33
34
Limit Switch Stop Assembly

Control Assembly - Reference Only - Parts
1 Limit Switch Trip Plate 2 398898-010A

2 Trigger Wheel, Position Indicator 1 398247-010B
3 Proximity Switch Mounting Bracket, TP500-E 1 398248-010A
4 Deleted * N/A
5 Limit Switch Mounting Plate (2 switch plate) 1 398383-010A
6 40 x 30 Beta Duct, 175mm Lg. 1 849575-9194
8 M5 Lockwasher, Shakeproof 16 879011-3200
11 M5 x 0.8 x 5 Lg. Hex. Hd. Cup Pt. Grub Screw 1 876006-3205
13 M8 Washer, Form-C 6 879006-4002
16 M8 Washer, Form-A 2 879006-4000
17 Air Trip Plate 2 398899-010A
19 Rail Nut, Twin Face 12 398360-010B
20 CP 2020 Rail x 300mm Lg. 4 398494-A0300
21 Energy Chain Assembly 1 399010-0062
23 M8 x 1.25 x 20Lg Hex. Soc. Hd. Screw 4 875007-4020
24 Limit Switch Mounting Plate (1 switch plate) 1 N1121812-C128
25 Energy Chain Mounting Block 2 398976-010A
26 Energy Chain Mounting Plate 1 398976-010B
27 M10 x 1.5 - 20 Lg. Hex. Hd. Screw 2 875005-4420
29 M10 Washer, Form-C 2 879006-4402
30 Csk Screw M5 x 0.8 x 20 Lg 8 875004-3220
31 Tow Bracket, TP-500 1 398954-010A

7.8 Control System - Proximity Switch
0.1 – 1.0
Switch / Wheel Gap
17-18
16
2-3
1
4
11-12 8
10
13-14-15

Limit Switch & Control Assembly - Parts – Typical Assembly - Reference Only
(For Contract Specific Layout of Encoder Refer to Wiring Diagram at End of Instruction Manual)
1 Duct 1
2 M6 Lockwasher, Split Type 2
3 M6 x 1.0 x 10 Lg. Slotted Pan Head Screws 2
(For Contract Specific Layout of Encoder Refer to Wiring Diagram

4 Tow Bracket 1
5 M8 Washer, Form ‘C’ 6
6 M8 x 1.25 x 20 Lg. Hex. Hd. Screw 4
8 M8 Washer, Form ‘A’ 2
9 Energy Chain Mounting Block 2
10 Energy Chain Mounting Plate 1
11 M8 Lockwasher, Split Type 4
at End of Instruction Manual)

12 M8 x 1.25 x 16 Lg. Hex. Soc. Hd. Screw 4
13 M10 washer, Form -C 2
14 M10 Loackwasher, Split Type 2
16 Proximity Switch Mounting Bracket 1
17 Trigger Wheel, Position Indicator 1
18 M5 x 0.8 x 5 Lg. Hex. Soc. Hd. Cup Point Grub Screw 1
19 Double Limit Switch Bracket 1-2
20 Single Limit Switch Bracket 1
21 M6 Lockwasher, Split Type 3-6
22 M6 x 1.0 x 16 Lg. Hex. Hd. Screw 3-6
23 M6 x 1.0 x 80 Lg. Hex. Hd. Bolt 3
24 M5 Lockwasher, Split Type 6-8-12-16
25 M8 x 0.8 x 40 Lg. Slotted Pan Head Screw 2-4-6-8
26 Spacer, 40mm 3
27 Spacer, 20mm 3
28 CP Rail 2-3-4
29 Twin Face Nut 8-12-16
30 M5 x 0.8 x 20 Lg. Hex. Soc. Hd. C’Sink Screw 4-6-8
31 M5 Plain Washer, Form ‘C’ 4-6-8
32 Air Trip Plate 1-2
33 M5 x 0.8 x 16 Lg. Hex. Soc. Hd. Screw 4-6-8
34 Trip Plate 2

7.9 Probe Tube Assembly – Air Cooled & Non Air Cooled - (Typical)
10
Tip Shield
Thermoprobe
13
11
12
Guide
Air Outlets
3 (Nozzles)
Air Cooled Probe

9-7
Hex Plug
7-8-9 6
12
1-10
6
2
6
7-8-9
Non Cooled Thermoprobe Assembly
13

Control Assembly - Parts – N1183614-C023
1 Follower, Probe Tip 1 330520-1125

2 Tip Shield, Thermoprobe 1 330521-1124
3 Gland Adapter, TP500-E 1 398229-010A
4 Manifold, TP500-E 1 398384-010A
5 Valve Stem Packing (2 - 3 Rings) 1 398443-010A
6 Probe Tube Assembly 1 N1183614-C024
7 M12 x 1.75 - 45 Lg. Hex. Soc. Hd. Screw 10 875007-4837
8 M12 Washer, Form-A 4 879006-4800
10 Sealant 1 908505-0010
11 "1"" x 90° Elbow, MI" 2 933800-8909
12 "Nipple, 1"" NPT x 7 3/4"" Lg." 2 935900-8771
13 Thermocouple 1 399588-10090KB

7.10 Air Inlet Manifold & Control Assembly
6
4 5
7
1 22
10
9
20 19
8
3
4 21
13-14-15
16-17
12
19
16-18
13-14-15
2

7.11 Air Inlet Manifold &Control Assembly - Parts - 398952-000A
1 Air Inlet Plate 1 398953-010A

2 Clamp Rail 1 398980-010A
3 Parker Clamp Set RAA10-5R1 2 902225-8901
4 1" x 90° Elbow, MI 4 933800-8909
5 Nipple (Close) 3 941416-0005
6 Nipple R1 x 70lg Galvanised 2 941416-0015
7 Equal Tee Rc1 2 941414-0013
8 Solenoid Valve (110V AC) 1 939871-9012
9 Flow Regulating Valve 1 939821-8906
10 Hex Bush R1-Rc¼ 1 941410-0013
11 Nipple 1 399274-F1BBA060
12 Pressure Switch 1 847356-9032
13 M8 Washer, Form-C 4 879006-4002
19 Male Stud Coupling 2 930711-9026
20 Nylon Tube Ø6mm (ft) 1.700 908904-8916
21 Inside Hose 1 398414-6280
22 Outside Hose 1 398414-6390
23 Nipple, G1 - R1 1 399274-F1ABA060

7.12 Wallbox - Negative Pressure
4 5
3 7
2
8
Wallbox – Negative Pressure – Parts – (397142-4A10)

1 Flange Arrangement 1 397142-000D
2 Seal Plate 1 397145-010A
3 Washer 1 869006-3600
4 Spacer 1 396938-010A
5 Washer 2 302072-0110
6 Compression Spring 2 908610-8906
7 Jam Nut 4 873008-4800
8 Split Pin 2 873607-4841
Note. Run one nut up to contact spring. Tighten the nut by two flats.
Fit the second nut and lock against the first.
If applicable, the seal plate machined face should be fitted towards the flange.

7.13 Rear Support Assembly
2 Rear Support Lugs (Ref Only)
3
2
4
6 5
Rear Support Assembly – Parts – 397736-000A

1 Rear Support Bar 1 397736-010A
2 M24 x 3.0 SCREWED ROD. ZINC PLATED, 250mm LG 2 RZ240130KC-0250
3 M24 x 3.0 HEX NUT 4 873015-6000
4 M24 washer 4 879006-6000
5 3/16" x 2" LG. SPLIT COTTER PIN, SHERADIZED 2 863607-2240
6 1 1/4" washer, sherardized 2 869006-3600

7.14 Auxiliary Support
Auxiliary Support Assembly – Parts – (399259-000A)

1 Auxiliary Support Assy - TP500 2 399259-000A
M10 x 25 Hex Hd. Screw 1 875005-4425
Fixing Screws M10 Washer, Form-C 1 879006-4402
M10 x 1.5 Nylock Nut 1 873013-4400

8. RECOMMENDED SPARES LIST
Diamond Power Thermoprobes have a Guarantee as specified in the customer contract. Beyond this
period and to cover any unforeseen problems due to system or component failures, it is advisable to
maintain a small quantity of frequently used spares. This will reduce to a minimum, any downtime and will
prove to be a cost effective way of maintaining the effiency of the supplied units.
The quantities noted in the colums within the tables are based upon holding a stock of components
per 10 installed units. Additionally, account must be taken of the actual usage of the units and number of
a cycles per day/year. For recommended stock levels for units in excess or less than 10 increase or
decrease to suit your unit quantity.
Usage Table
Cycles Per Cycles Per 50 Week

Quantiy of Recommended Spares to be Held
Day/Week/Year Period
Column 1 - Day 3 per Day 1050 per 1 Year

Column 2 - Week 21 per Week 2100 per 2 Years
Column 3 - Year 1050 – per Year 3150 per 3 Years
Item/Page Number refer to the page within this manual that the component is depicted.
Item/Page No. Description Part No. 1 2 3
Carriage Assembly – 398951-R000

3 38 Pinion Shaft 398213-010B 1
6 38 Ball Bearing 901110-0049 2
7 38 12T Pinion 324188-1121 2
11 38 Gasket, Motor Frame 343831-1130 1
Main Assembly
* 36 Electric Motor N11836-861 1

36 Limit Switch Assy - Siemens 841405-0161 3
*
36 Flow Regulating Valve 939821-8906 1
*
36 Solenoid Valve 939871-9012 1
*
36 Pressure Switch 847356-9032 1
*
36 Energy Chain 399010-0061 1
*
Carriage Roller Assembly
2 40 Ball Bearing, 901110-0049 2
9 40 Roller Assembly 324124-1029 2
13 40 Key, 1/4" Sq. x 1.625" Lg 306037-7110 2
14 40 Internal Retaining Ring, 80 x 2.5, N5000-315 907920-0066 4
15 40 External Retaining Ring, 40x1.75 907920-0080 4
17 40 907920-0010 2
External Circlip,63/64"x0.042", 5100-98
Roller Assembly Front Support
1 41 Roller – 3 ½” Lance 319546-1128 1
2 41 Ball Bearing 901110-8924 2
5 41 Shaft Roller 394056-2121 1

Item/Page Number refer to the page within this manual that the component is depicted.
Item/Page No. Description Part No. 1 2 3

Probe Tube Assembly – N1183614-C023
10 Drawing Tip Shield 330521-1124 1
14 Drawing Packing, Valve Stem 398443-010A 10 10
13 Drawing Thermocouple 399588-10090KB 1
Wallbox Assembly – 397142-4A10
2 81 Seal Plate 397145010A 1
4 81 Spacer 396938-010A 1

9. ADDENDUM TO INSTRUCTIONS
9.1 RISK ANALYSIS
After installation by competent and approved engineers, site Health & Safety Managers must ensure that
a regime of continual assessment of the installation is made in order to protect the supplied equipment
and any personnel coming into contact with it. Unless otherwise specified, all equipment supplied is fully
guarded and access to any moving components is prevented during normal operation. Additionally, areas
of the equipment can become very hot during normal use and operators must be made aware of a
potential burn risk.
Situations, such as detailed, but not restricted to those below, must be considered at all times.
9.2 Mechanical Hazards

Thermoprobe Supports: Installation Support Hardware is the responsility of the end user. All loading and
stress calculations required to support the equipment, must be made with reference to the equipment
loading as stated on the equipment nameplateand layout drawings.
Thermoprobe Installation Height: In any installation where a thermoprobe is at or below head height, the
end user must ensure that appropriate hazard warning notices are placed on or near the equipment to
avoid potential head knocks and trip hazard.
Equipment Guards: There is no electrical isolator or interlock connected to the guard assembly. Removal
of any individual section of guard must only be made after electrical connections have been isolated and
the probe returned to the rear rest position. Removal of guard sections will allow access to moving
components such as the carriage, front support rollers and rack & pinion drive. All of the moving elements
present a trap or entanglement hazard. The equipment should only be operated in an unguarded state by
competent personnel during maintenance activity.
9.3 Electrical Hazards
Contact With Live Parts: For any maintenance, in order to ensure that it is not possible to contact live
parts inside the terminal box or control panel, isolate the terminal box or control panel before accessing
any electrical components. Electrical work should only be done by skilled and professionally competent
employees.
Contact With Live Parts: (Fault Condition): Damage to any electrical cable could cause equipment to
become ”Live”. Ensure that equipment is earthed. Each sootblower and panel has an earthing provision.
Loss of Power: In the event of an unexpected power loss,the thermoprobe may be stopped within the
boiler. It is important, if this situation arises, that the probe assembly is returned to the rear stop position
manually to prevent damage to the lance or boiler tubes. Refer to section 2.4 of the instruction manual for
information on manual retraction of the lance.
Restoration of Power: Thermoprobe may start without warning as they are remotely controlled.
This should not cause additional hazard as long as Thermoprobe guards remain in place. Prior to guard
removal for any reason, electrical power supply must be isolated.
Unexpected Start: The sootblower may be started by a remote control system. To avoid crushing or
other injury, guards must be fitted at all times.
Stopping & Isolation: To comply with relevant directives and legislation DPSL supply thermoprobes with
guards which, as per our risk assessments, negate the need for Stop, Emergency Stop or Local Isolation
on the sootblower.
DPSL consider that each thermoprobe control system should include system stopping facilities as
required to bring the equipment to a safe condition in a safe manner.
Stopping an operating thermoprobe (or isolating which would cause the sootblower to stop) is not
recommended as the thermoprobe would then remain within the boiler which could cause consequential
damage to the probe assembly.
Control Systems in our supply are therefore normally provided with a System Shutdown facility which
typically operate as follows:-

(1) When actuated, the system shutdown procedure is initiated to bring any active thermoprobe to a
complete stop at its “rest” position
(2) In the rest position the thermoprobe is stationary as electrical energy to the thermoprobe motor is
removed. As our thermoprobe, when guarded, have no accessible dangerous parts, there is no
requirement for a “positive stop”.
(3) The shutdown procedure prevents any further operation of the system until reset and operation is
re-started by the operator.
Note
Regarding isolation, the electrical supplies to the thermoprobe system are provided with a means of
isolation at the supply source. Sootblowers should not be isolated until they have returned to the rest
position as described above. Any maintenance work on a thermoprobe system should only be carried out
when all electrical supplies are isolated and the system is at rest.
In many cases DPSL only supply a part of the sootblower system and we advise that the user should
ensure that each system is provided with stopping facilities and isolation facilities for all electrical supplies
as required to comply with relevant directives.
9.4 Thermal Hazards
Burns Due to Contact with Hot Parts: Contact with Wallbox, thermoprobe assy could cause burns. Contact
with these components is prevented by the use of guards. Do not make contact with these parts unless
power is isolated and correct protective clothing and gloves are worn.
Burns Due to Contact with pipework and Wallbox: Supply pipework should be insulated where possible to
prevent burns from contact. Limited access to wallbox during use should reduce burn risk but operators
must be made aware of hazard if they are required to work in close proximity for maintenance reasons.
9.5 Errors of Installation

An instruction manual together with a set of drawings is supplied to give guidance on installation.
Thermoprobe must be installed by suitably qualified personnel who must carry out a risk assessment
before commencing. Failure to comply with the installation, maintenance and lubrication instructions
contained within the instruction manual may compromise the warranty of the installed equipment.

10. TECHNICAL DATA SHEETS
10.1 Thermoprobe Layout Sheets
10.2 Thermoprobe Wiring Diagram
10.3 Probe Assembly
10.4 Motor Data Sheet

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S:\controls\ALL\All_drawings\drgs solidedge & cimcad\N11800-N11899\N11836\N11836-4-618-1E.dft
1 2 3 4 5 6 7 8 9 10 11 12
Item Qty Part No. Description Remark

Motor *shown for ref only
THIRD ANGLE PROJECTION

TP500-E Layout 1
2
*
*
Motor, M25 entry - see motor spec sheet.
Cable Chain
3 10m 849585-9315 Cable, motor power, 3+E core 2.5, Sy, braided, Lapp (Hopk) - RED, YELLOW, BLUE, G/Y CORES sleeve as req'd
A 23 25 8 9 24 A
4 2 841402-0108 Cable Gland, M25, Cable OD 13-15.8, 10-12 inner core, NiBrass, braided cable
5 * Entry, 25.4mm dia clearance hole (for M25)
21 21 6 1 841402-0057 Locknut, Cable Gland, Ni Brass, M25
17 1 2 Limit Switches
7 3 841405-0161 Limit Switch Assy, Metal Body, 2NO-NC, Snap Action, Roller Lever, M20, Schneider LSR, LSF,CMS
8 30m 849585-9445 Cable, Control, 9(8+E) core, White cores/black numbering, 450/750V, Black Sheath
9 12 841402-0067 Cable Gland, M20, Cable OD 7-13, Rd. Top, Nylon, Black
19 to 21 POSITION TEMP
10 * Entry, 20.5mm dia clearance hole (for M20)
11 11 841402-0078 Locknut, Cable Gland, M20, Nylon, Black
12 to 17 22 26 to 89 100 % 600 oC
T/C & Pos circ.
12 25m 849585-9369 Cable, Screened, 2-core+drain, twisted pair, 18awg 0.82mm2, 6mm OD Grey Sheath LSOH, Belden as req'd
13 4 841402-0098 Seal, Pg13.5/M20, Multi-Cable, O/D 2x5
3 4 5 14 25m 849585-9272 Cable, Thermocouple 'K' Extension, 2-core + screen, green, PVC
15 4 848300-9995 Terminal, 2-pole, Thermocouple 'K', 1-Cromel-Al pair, WDU2.5/TC TYP K
9 10 11 13 WARNING
Main MCB Isolating
WARNING
16 4 848300-9754 TL End Plate, TS35, for WDU2.5, 4 & 10
TP500-E
Switch Operation 17 4 848300-9753 Terminal, TS35, WDU2.5
Door Interlocked Transmitter kit
B LSR LSF B
18 1 847340-9096 Encoder, 2-phase, Round M12, 4-wire, Baumer electric, 4-core x 2m Cable tail.
2 I
19 # 1 843209-9073 Ramp Generator, NPN & PNP I/P, 4-20mA O/P (24VDC)
LOC/REM READY INSERT RETRACT STOP 20 # 1 843209-9075 Socket, 11 pole base for PR devices, PR type 7023
CMS 21 # 2 843209-9100 LCD Indicator, 24-230VAC 24-250VDC, programmable input, 4-20mA output Temperature
7 8 9
0
22 2 841402-0001 Cable Gland, M20, Cable 4-7mm O/D, Nylon, Black, with nitrile sealing washer and locknut for encoder & T/C cable
7 8 9 BK WH WH G R
Dual TC A ncillaries
Type 'K' 23 * Cooling Medium Valve Assy
24 * Pressure Switch (for Cooling Medium)
7 8 9 CAUTION 25 10m 841404-0014 Cable, HiTemp flexible, 3x1.5mm core (2+E) 8mm OD, white outer sheath sleeve cores red
* ISOLATE ELSEWHERE BEFORE Enclosure
ACCESSING ANY TERMINALS 26 # 1 N1183612-C025 Enclosure & Fittings Assy, 600Hx800Wx250D, Sheet Steel 2mm thick, IP65, RAL7032
* UNIT MAY START 27 # 6 848300-9751 Terminal, TS35, WDU6, (800V/57A max), 0.5 to 10mm2 conductor. Weidmuller WDU6
UNEXPECTEDLY 28 # 2 848300-9752 TL Partition, TS35, WDU10, for WDU2.5, 4 & 10
29 # 2 848300-9844 Terminal, Earth, Power Circuit, TS35, WPE6 Weidmuller WPE6
30 # 2 848300-9080 Support Bracket for ADP, Polyamide 6.6
31 # 0.1m 848300-9079 Cover, Transparent
A B B B B B C C 32 # 14 848300-9755 TL End Bracket, TS35, EW35, for WDU2.5, 4 & 10
C 91 58 92 93 90 33 # 37 848300-9768 Terminal, TS35, WDU4 (750V/35A) Weidmuller WDU4 C
d=20.5 34 # 10 848300-9754 TL End Plate, TS35, for WDU2.5, 4 & 10
d=25.4
35 # 1 848300-9783 TL Cross Connector, 2 WAY for WDU 4, WQV 4/2
36 # 7 848300-9779 Terminal, Earth, Control Circuit, TS35, WPE4
Incoming 37 # 17 848300-9967 Terminal, double deck, 2-way, TS35 Rail, type WDK 4N Weidmuller WDK4N
Mot LSR LSF CMS CMV PS Pos Temp Supply Interconnecting Cables to 38 # 4 848300-9963 Terminal, double deck, 4-way, TS35 Rail, type WDK 4NV
39 # 7 848300-9885 End Plate, for double deck WDK..N type terminal
Cable entries at rear of panel from
PDP B
PDP B 40
41
#
#
2
1
848300-9984
848301-0004
TL cross Connector, 2 WAY for 4N
Earthing Bolt Kit, M10, SS304 - supplied loose for panel earth
42 # 0.7 849571-9243 Cable sleeving, Heat shrink 2.4mm², Red For sol cable cores
43 # 0.7 849571-9249 Cable sleeving, Heat shrink 4.8mm², Yellow For motor cable cores
44 # 0.7 849571-9287 Cable sleeving, Heat shrink 4.8mm², Red For motor cable cores
45 # 0.7 849571-9288 Cable sleeving, Heat shrink 4.8mm², Blue For motor cable cores
A = 4, 5, 6 46 # 10m 849585-9293 Wire, 1.0mm, 500V, Halogen Free, IEC 60332.1/3, 125oC, Blue
47 # 60m 849585-9295 Wire, 1.0mm, 500V, Halogen Free, IEC 60332.1/3, 125oC, Red
B = 11, 12, 13 800 48 # 10m 849585-9324 Wire, 2.5mm, 750V, LSOH, IEC 60332.1/3, 125oC, Red
49 # 10m 849585-9325 Wire, 2.5mm, 750V, LSOH, IEC 60332.1/3, 125oC, Yellow
D C = 9, 10, 11, 13 50 # 10m 849585-9326 Wire, 2.5mm, 750V, LSOH, IEC 60332.1/3, 125oC, Blue D
51 # 10m 849585-9309 Wire, 2.5mm, 750V, LSOH, IEC 60332.1/3, 125oC, G/Y
52 # 1 907506-8927 Label, "Warning - Thermoprobe", English fit before shipping
53 # 1 907506-8954 Label, "Warning - Thermoprobe", Vietnamese fit before shipping
54 # 1 907506-8904 Label, WARNING, Main MCB Isol. Switch.
55 # 4 847313-9208 VCI Foam Square, corrosion protection for motor & sootblower terminal boxes
56 # 2 866507-8902 Self tap screw, No.4x8mm A2, SS
57 # 1 N11836-LB02 Nameplate, stainless steel, black engraved/lasered lettering, engraved as shown
58 # 1 * Entry, 25.4mm dia clearance hole
Starter Kit
59 # 1 842800-9385 Door Coupling Mech. for Rockwell MCB 140M-D, R/ Y Handle
60 # 1 842800-9318 MCB/TOL, FLC 1.6 - 2.5A
61 # 1 842800-9386 Extension Shaft, for Rockwell Door Coupling Mech
Enclosure 62 # 1 842800-9398 Aux. Contacts, 2 NO , for Rockwell 140M MCB/TOL
63 # 1 842800-9482 MCB, 2-pole, 4A, 'C' trip
600H x 800W x 250D 64 # 2 846400-9344 Contactor, 110V 50/60Hz, 3-Main pole, 1-NO
Single hinged door, 65 # 1 846400-9345 Locking Mech. for 100-C ContactorS (REV. MC)
E
Frame & Doors - 2mm thick 66 # 1 846400-9413 Electrical interlock bus bar for 100-C Contactors E
Mounting Plate - 2mm thick 67 # 2 846400-9430 Aux contact, 2-NO + 2-NC, front mounting for 100C contactors
Material - Carbon Steel 68 # 1 846431-9304 EOL, 1.0-5.0A, 1 NO & 1NC Aux Contact, AUTO/MAN Reset
600
69 # 1 846431-9302 DIN Rail/Panel Adapter for 846431-9303,4 type EOL
Ingress - IP65 minimum 70 # 1 846400-9329 Relay Base, 4-CO, DIN MT, 30mm
Paint spec - RAL 7032 (textured) 71 # 1 846400-9325 Relay, Plugin, 24VDC, 4-CO, c/w LED
72 # 8 846400-9433 Base, 8-pin, 16mm wide, DIN rail mount, c/w clip, black
73 # 8 846400-9435 Relay, PlugIN 16mm, 24VDC, 2-CO, LED
74 # 1 846421-9282 Multi Function Time Delay Relay 24VDC/230VAC supply SPDT
75 # 1 847313-9134 Rail, TS35 x 2m LENGTH, Unslotted, Top HAT DEEP
76 # 1 847360-9393 Pushbutton, White, Illuminated, Signum 3SB3 insert
77 # 1 847360-9391 Pushbutton, Red, Illuminated, Signum 3SB3 stop
78 # 1 847360-9392 Pushbutton, Illuminated, Green, Signum 3SB3 reverse
79 # 2 847360-9358 Contact Block, 1-NO
80 # 1 847360-9360 Contact Block, 1-NO + 1-NC
81 # 1 847360-9361 Contact Block, 2-NO
82 # 2 847360-9362 Contact Block, 2-NC
83 # 1 847360-9385 Selector switch, 2-position, non-illuminated, black, including holder, Signum 3SB3
F F
84 # 5 847360-9400 Nameplate Holder
250 85 # 1 847360-9398 Indicator, White, Signum 3SB3 ready
86 # 1 847360-9364 Lampholder, LED, Red, 24VDC, Signum 3SB3
Removable Gland Plate 87 # 1 847360-9365 Lampholder, LED, Green, 24VDC, Signum 3SB4
88 # 2 847360-9367 Lampholder, LED, White, 24VDC, Signum 3SB5
89 # 1 N11836-LB01 Label set for PB & Lamp, 5 labels total, engraved as shown "LOC/REM", "Ready", "Insert", "Retract", "Stop"
Contract Specific Requirements
90 # 3 * Entry, 36mm dia. clearance hole
91 # 1 849517-8963 Cable Gland, 25mm, Nickel Plated Brass, for customer cable (non-armoured)
92 # 1 * Entry, 28mm dia. clearance hole
General Arrangement 93 # 1 * Entry, 50mm dia. clearance hole
=> N11836-618 Electrical Parts Assembly, TP500-E
N11836-618TB Starter Assy, populated, TP500-E assy of # parts only
WARNING
G Do not operate locally unless permitted to do so. G
Do not carry out maintenance until blowing supply is locked OFF.
Do not carry out maintenance until all voltage supplies are locked OFF
Notes
1 - Unit is shown in rest position with LSR actuated.
2 - Internal wiring is by DPSL, interconnecting cable and glands by LMB. TP500-E
3 - Any voltages shown are actual volts carried by the cable, they do not show size or rating of cables.
4 - A cable loop should be arranged to allow for boiler expansion.
5 - Installer to ensure incoming earth is connected to PE terminal as required by local regulations.
TP500-E THERMOPROBE WIRING DRAWING
H H
THIS DRAWING AND THE INFORMATION IT CONTAINS Rev DATE REVISION BY CH Rev DATE REVISION BY CH Rev DATE REVISION BY CH Rev DATE REVISION BY CH DRAWING STANDARDS BASED ON
DIMENSIONS ARE IN MILLIMETRES UNLESS OTHERWISE STATED
HAVE BEEN FURNISHED FOR USE BY YOUR OWN A 09 Mar 2017 First Issue P.T. R.A. BS 308
ORGANISATION ONLY AND FOR PURPOSES
CONSISTENT WITH THE TRANSACTION BETWEEN B 29 Mar 2017 Updated for client comments (Entry holes) GE PT DRAWN BY gerwin DATE: 07 Jul 2017 SCALE: N.T.S A1
YOUR ORGANISATION AND DIAMOND POWER. NO C 06 June 2017 Updated for client comments (M25 gland -> M20, Entry hole 36mm Dia.) GE RA
COPIES OF OR DATA FROM THIS DRAWING SHALL BE SHEET 1 OF 3 Rev
FURNISHED TO ANY THIRD PARTY WITHOUT THE D 29 June 2017 Updated entry details as per DHI comments GE GE CHECKED BY R.Allan
WRITTEN AGREEMENT OF DIAMOND POWER
SPECIALTY LTD. DUMBARTON SCOTLAND.
E 07 July 2017 Item 93 added for (DHI field cabling entry requirement for 19-core cable) GE RA
APPROVED BY P.Thompson N11836-4-618 E
1 2 3 4 5 6 7 8 9 10 11 12
S:\controls\ALL\All_drawings\drgs solidedge & cimcad\N 11800-N11899\N11836\N11836-4-618-2E.dft
1 2 3 4 5 6 7 8 9 10 11 12
THIRD ANGLE PROJECTION Door interlocked, Schematic of Power & Control Circuit Electronic Overload Notes
open in 'O' Range - 1.0 - 5.0A
A MCB/TOL A
position only. Set - 1.5A
Range - 1.6 - 2.5A
O I Set - 1.8A for TP
Auto Reset
Local/Remote Selector = switch must be selected to REM to enable remote Insert and Stop
Manual Reset FA1.1 commands. Remote reverse is enabled at all times to allow the DCS operator to retract the TP.
400V 3ph 50Hz
L1
QM1.1 L4 KM1.1 L7 U
Incoming
Supply
2 1 1 2
M
L2 L5 1 2 L8 V
L3 4 2
L6 3 4 L9 3 4 W Remote Insert = remote Insert momentary pulse starts the TP forward.
6 3 5 6 5 6 The TP then runs forward to the front position and stops.
PE
PE When the LSF signal advises that the TP is at the front position the TP can be left for a short
KM1.2 period to read the temperature then the TP should be retracted by Local or Remote Reverse
PE
FA1.1 trips instantaneously to stop the TP on motor overload. command.
1 2
If the motor overload persists the MCB/TOL trips to cut the supply
MCB 3 4 and stop the motor. The TP should not be left at the front position for a continued period (typically 30s max)
Turn MCB/TOL handle to O then to 1 to reset.
B QF1.1 5 6
If necessary retract the thermoprobe by hand.
B
2x4A
Remote Reverse = remote Reverse momentary pulse reverses the TP.
24VDC Supply
Char C
(From PLCP)
TO SHEET 3
Incoming
24V 13 14 J1A 1 2 J1 J1
0V 21 22 J2A 3 4 J2 J2
Remote Stop = stops the TP, it can then be re-started in either direction by Insert or Reverse.
PE
Do not stop the TP for a continued period (typically 30s max).
Note that if the TP is stopped by remote Stop then Faults FA1.1 overload, High Temp, or Low
PE Press will override the Rem Stop to retract the TP.
'STOP'
J3 Stop
LSR = TP rear limit switch tripped (indicates that the TP at rest)
J13 J26
LSF = TP front limit switch tripped (indicates that the TP fully inserted)
KA2.3
C C
J4 KA1.3 KA2.3 TP Ready = ON signal indicates Ready, the TP MCB/TOL is ON, and all voltages & alarms are
healthy.
'LOC'
= OFF indicates combined TP Fault.
TO SHEET 3
J17
'REM' KM1.1 KA2.1 0 = HIGH On Faults Electronic Overload FA1.1 trip, High Temp or Low Pressure if the TP is operating it will
J5 J14 TEMP (N/C
KA1.4 contact of J25 be retracted automatically.
'INSERT' J22
temp
indicator)
KM1.2 KA1.3 KA2.2 KA1.1 KM1.1 KM1.2 Caution
J6
J15
If the TP Ready/Fault signal goes OFF the operator should check the TP immediately to ensure it
'RETRACT' KT1 = TIMER FA1.1 is at rest and retract by hand if necessary. Extended periods in the boiler with or without cooling
J10 J18 J20 (0.1s-120h Range) J23
D
J7 Set at 5s air can damage the probe tube. D
J12 KM1.1 KA1.2 DELAY ON
KA2.2 KM1.2 J19
ENERGISE KT1
J11 J16
J8 J21 J24
KM1.1 KA1.0 KM1.2 KA1.1 KA1.2 KT1 KA1.3 KA1.4
KA1.3 MI TP-500E WIRING
J9
POWER
Insert Retract 400VAC 3ph 50Hz 2.5mm², RED, YELLOW, BLUE
COUNTER RESET Ready
- see SHEET 3
J33 J34 J31 J32 J35 J36
TP EARTH 2.5mm² GREEN/YELLOW
Starter X3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34
CONTROL
E
TP500-E 24VDC 1.5mm², BLUE E
1 2
14 13 14 13 14 13
12 11 12 11 12 11 LIMIT SWITCH WIRING - BLACK SHEATH, WHITE CORES, BLACK NUMBERING

PRESSURE SWITCH WIRING - BLACK SHEATH, WHITE CORES, BLACK NUMBERING
24 23 24 23 24 23
SOLENOID VALVE WIRING - WHITE SHEATH, RED CORES
22 21 22 21 22 21
CMV
TERMINALS, STANDARD
LSF LSR CMS
PS NB: All DCS Remote Control, Positional & Temperature Feedback for
TP1 (P1HBK10CT001 for Unit 1 / P2HBK10CT001 for Unit 2)
SB Panel (PDP B) Interface Circuit 1 mom = 1 mom = 1 mom=
and TP2 (P1HBK10CT002 for Unit 1 / P2HBK10CT002 for Unit 2)
F
Remote Remote Remote Via Interface with PDP B F
Insert Reverse Stop ( P1HCB20GW002 for Unit 1 / P2HCB20GW002 for Unit 2)

J71A J75A
'REM' 'REM'
KA1.3 KA1.4 KM1.1 KM1.2 'LOC' KA2.1 KA2.2 KA2.3
J31 J32 J33 J34 J35 J36 J38 J40 J42 J44 J46 J71 J73 J75
J72 J74 J76

J37 J39 J41 J43 J45 Abbreviations
X6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X7 1 2 3 4 5 6 LSR = Limit Switch Rear
LSF = Limit Switch Front
G CMS = Cool ing Medium Switch G
CMV = Cooling Medium Valve
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 PS = Pressure Switch
TP = Thermoprobe
1 = TP 1 = TP Pressure 0 = TP Fault 0= High 1 = MFC ON 1 = MRC ON 1 = LOCAL TC = Thermocouple
at Rear at Front Switch 1 = TP Healthy Temp 0=REMOTE Pos = Position
Position Position Position Temp = Temperature
(Ready) Alarm PLC or DCS REMOTE HARD-WIRED CMDS KM = Contactor
LSR LSF VIA PDP B PANEL KA = Relay
KT = Timer
QM = Breaker
MCB/TOL = Magnetic Circuit Breaker/Thermal Overload
TP500-E / P1HBK10CT001 MFC = Motor Forward Contactor
MRC = Motor Reverse Contactor
FA = Fault Relay TP500-E THERMOPROBE WIRING DRAWING
H H
CONSISTENT WITH THE TRANSACTION BETWEEN B 30 Mar 2017 Updated to align with current PLCP design GE PT DRAWN BY G. ERWIN DATE: 06 Jun 2017 SCALE: N.T.S A1
YOUR ORGANISATION AND DIAMOND POWER. NO C 13 Apr 2017 Updated to add KKS and interface details GE GMT
FURNISHED TO ANY THIRD PARTY WITHOUT THE D 06 Jun 2017 KKS Signal number removed for clarity and note added GE GE CHECKED BY R.Allan
E 16 Jun 2017 Drawing revised for DHI comments GE GE
APPROVED BY P.Thompson N11836-4-618 E
1 2 3 4 5 6 7 8 9 10 11 12
S:\controls\ALL\All_drawings\drgs solidedge & cimcad\N11800-N11899\N11836\N11836-4-618-3F.dft
1 2 3 4 5 6 7 8 9 10 11 12
THIRD ANGLE PROJECTION Schematic of Position & Temperature Circuit Internal Layout
A A
SETPOINTS
Tmax without cooling air = approx 593oC. X1 X3 X4 X5
Tmax with cooling air = approx 816oC. J9 J34 J31 J12 J17 J19 J19 J36 J2 SCR UP DN TTX2 TTX2
SCR SCR TTX1 TTX1
COUNTER
UP/DOWN
J1
TX1+ GREEN Set Point for High Temp Retract = approx 800oC J33 J10 J1 J32 J12 J2 J35 J21
+ - + -
DUAL
TX1- WHITE
THERMOCOUPLE
Low Pressure = 22 psig (2.53 barg) 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34
TX2+ GREEN POSITION - see TP Ins Manual. U V W PE 1 3 5 7 PE 9 11 13 15 PE 17 19 21 23 PE 25 PE 27 29 31 33 PE 1 2 3 4 5 1 2 3 4 5 6
TX2- WHITE UP/DOWN
J1 BROWN
COUNTER
POSITION ENCODER - UP/DN MAY to PE
UP WHITE
BE SWAPPED TO CORRECT UP/DOWN Stud
DN BLACK
B COUNT IF REQUIRED. B
J2 BLUE LSF LSR CMS CMV PS
Prox Sw Thermocouple
SCRN
Contact opens
JUNCTION BOX on high temperature.
POSITION INDICATOR TEMPERATURE INDICATOR
0 0.0 0 J1 21 22 23 24 25 26
0 0.0 0 QF KA KA KA KA KA KA KA KA
21 22 23 24 25 26 QM1.1 KM1.1 KM1.2 FA1.1 1.1 KT1 1.0 1.1 1.2 1.3 1.4 2.1 2.2 2.3
41 42 43 44 45 46 11 12 31 32 J25 41 42 43 44 45 46 11 12 31 32
J1 J1
C CABLE CHAIN
P2 P1 J2 T1 T2 J2 C
PULSE
UP/DOWN
COUNTER
9+
J1
X0 X2 X6 X7 X8
10 -
J2 P1 P2 SCR T1 T2 SCR
KA1.0
RESET
J1 J27 4-20mA
FROM SHEET 2
11
SIGNAL L1 L2 L3 PE 24V 0V SPR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 PE 1 2 3 4 5 6
PE
J1 UP UP
1 X2 STUD
D 4 pnp D
CHANNEL 3
J2 X1
TX2+
TX1+
TX2-
TX1-
SCR
SCR
SCR
DN DOWN SCRN
DN
UP
J1
J2
POWER CABLE CONTROL SUPPLY CABLE PDP B Interface Cable Temperature/

400V 3PH 50Hz 24VDC 24Vdc Position Signal Cable
4-20 mA
4 - core (3+E) 4 - core (3+E) 19 - Core (18+E) Analog
4mm2 / OD 18mm 2.5mm2 1.5mm2 2 - Pair 1.5mm2
M25 Gland by DPSL 50mm dia clearance hole 36mm dia clearance hole
28mm dia clearance hole
Incoming Supply Interconnecting Cables to local control panel - PDP B

SCR
SCR
P1
P2
T1
T2
E E
ALL FIELD CABLES BY OTHERS
J1 & J2 TEMPERATURE
NB: All DCS Remote Control, Positional & Temperature Feedback for
POSITION
Marshalling SIGNAL SIGNAL TP1 (P1HBK10CT001 for Unit 1 / P2HBK10CT001 for Unit 2)
4-20 mA 4-20mA and TP2 (P1HBK10CT002 for Unit 1 / P2HBK10CT002 for Unit 2)
Via Interface with PDP B
( P1HCB20GW002 for Unit 1 / P2HCB20GW002 for Unit 2)
F F
Pulse Up/Down Counter Settings Position Indicator Settings Temperature Indicator Settings
Type - PR2281 IN - current IN - temp
Input - PNP 24VDC Range - 4-20mA TYPE - TC
PUP - HLd DEC.P - 11.11 TCTY - TC.K
RES - 0.00 DILO - 0 DEC.P - 111.1
PRE - 001 DIHI - 9.07 UNIT - oC
UHI - 027 A.OUT - 4-20 REL 1 - SET
ULO - 210 0.ERR - 3.5mA SETP - 815
dHI - 027 RESP - 0.4 ACT1 - INCR
dLO - 210 EPAS - no HYS1 - 1
OL - 4.00 ERR1 - ACTI
OH - 20.0 ON.DE - 10
G U1 - 002 OF.DE - 10 G
OR - off REL2 - OFF
FUn - 003 AOUT - 4-20mA
EFS - dFS O.LO - 0.0
FLt - HI
PAS - 040
O.HI - 1000
O.ERR - 3.5mA
TP500-E
RESP - 1.0
E.PAS - NO
TP500-E THERMOPROBE WIRING DRAWING

H H
CONSISTENT WITH THE TRANSACTION BETWEEN B 30 Mar 2017 Updated to align with current PLCP design GE PT DRAWN BY gerwin DATE: 07 Jul 2017 SCALE: N.T.S A1
YOUR ORGANISATION AND DIAMOND POWER. NO C 12 Apr 2017 Control connections through PLCP (not PDP A as before) GE GMT
FURNISHED TO ANY THIRD PARTY WITHOUT THE D 06 Jun 2017 KKS No's removed for clarity, and note added GE GE CHECKED BY R.Allan
E
F
16 Jun 2017
07 July 2017
INTERFACE UPDATED FOR DHI COMMENTS
19-core cable now 50mm dia clearence hole by DHI request.
GE
GE
GE
GE
APPROVED BY P.Thompson N11836-4-618 F
1 2 3 4 5 6 7 8 9 10 11 12
K:\N11800-N11899\N11836\02_Engineering\Drawings\N1183614-C023 Probe Tube & Manifold Assy.dft
1 2 3 4 5 6 7 8 9 10 11 12
UNLESS OTHERWISE STATED
BREAK SHARP EDGES Qty Item Part No. Description
LINEAR TOLERANCE: ±1mm
ANGULAR TOLERANCE: ±1° 1 1 330520-1125 Follower, Probe Tip
SURFACE FINISH: 3.2µm
THIRD ANGLE PROJECTION 1 2 330521-1124 Tip Shield, Thermoprobe
A 1 3 398229-010A Gland Adapter, TP500-E A
6
1 4 398384-010A Manifold, TP500-E
5 1 5 398443-010A Valve Stem Packing (2 - 3 Rings)
3
1 6 N1183614-C024 Probe Tube Assembly
10 7 875007-4837 M12 x 1.75 - 45 Lg. Hex. Soc. Hd. Screw
4 8 879006-4800 M12 Washer, Form-A
USE LOCTITE 572 PIPE SEALANT
ON TAPER THREADED FITTINGS 10 9 879016-4800 M12 Lockwasher, Form A
1 10 908505-0010 Sealant
2 11 933800-8909 1" x 90° Elbow, MI
2 12 935900-8771 Nipple, 1" NPT x 7 3/4" Lg.
1 13 See BOM Thermocouple
B B
Note:
Assembly shown for RH Thermoprobe. For LH variant, adjust the orientation of

6 the elbows (item 11) to suit.
DETAIL B
1:1.5
6 10 1 2
C C
C
B
SECTION A-A
1:2 6
3
D D
DETAIL C A
1:1.5
13 7 9 8 4 6 9 7 1:2
11 11 LH ORENTATION OF ELBOWS
E E
11
12
12 12
F F
G G
Part Number: N1183614-C023
1:2 1:2
PROBE TUBE & MANIFOLD ASSY - AIR COOLED
(DYE PEN TESTING)
H H
HAVE BEEN FURNISHED FOR USE BY YOUR OWN A 10 Jul 2017 First Issue G.S. J.B. BS 308
CONSISTENT WITH THE TRANSACTION BETWEEN DRAWN BY G.Sharp DATE: 03 Jul 2017 SCALE: N.T.S A1
YOUR ORGANISATION AND DIAMOND POWER. NO
FURNISHED TO ANY THIRD PARTY WITHOUT THE CHECKED BY J.Bennett
SPECIALTY LTD. DUMBARTON SCOTLAND. APPROVED BY A.Wylie N1183614-C023 A
1 2 3 4 5 6 7 8 9 10 11 12
NUMBER REV
SPECIFICATION SHEET - MOTOR 844617 - 9401 E

GENERAL
Application IK1M Sootblower, TP500-E Thermoprobe Motor
Maker WEG
Maker's Part Ref. W22 ref 342009/2012-A/B
FRAME
Type S.C.I.M.
Size 80 (Total length including shaft ‘L’ = 276 see Note)
Mounting IM3001 (B5) (Flange, Shaft Horizontal, No Feet)
Enclosure T.E.F.C. (IC 411) IP55
Frame Material * Cast Iron
Paint spec Makers standard
Colour Makers standard
Humidity suitable for 95% relative humidity
Drain No drain holes (if fitted plug to IP55)
Nameplate S\S (on RHS when facing DE) VIEW FACING DE
TERMINAL BOX Note for IK1M only

Type Screw terminals Total motor length
Position On top (when facing DE) including shaft
Material Cast Iron ‘L’= 273.5 max.
Entry M25 (entry on LHS when facing DE) If motor is fitted before
Earth Internal earth terminal gearbox is fitted then
‘L’ = 300 max can be
SHAFT accepted.
Diameter 19mm (40mm long M6x16 tapped hole)
Oil / Dust seal Oil seal at drive end, makers standard at non drive end.
ELECTRICAL
Output 0.55kW (50Hz); 0.63kW (60Hz)
Power supply 380 to 420V 3ph 50Hz / 440 to 480V 3ph 60Hz - Star supplied STAR connect
220 to 240V 3ph 50Hz / 250 to 280V 3ph 60Hz - Delta
Supply variation Voltage as shown above 5%. (with B temp rise)
In addition voltage 10% variation (with F temp. rise).
Frequency variation 2%
Insulation Class F with class B temp. rise
PERFORMANCE
Speed 1500 rpm @ 50Hz / 1800 @ 60Hz (4 pole) (actual 1410 / 1710)
Rating S1 @ 40oC & 1000 masl
S2 15min @ 60 oC (@ nominal voltage range) (with F temp. rise)
S2 15min @ 2000masl (@ nominal voltage range) (with F temp. rise)
Rated current 1.34 A @ 400V 50Hz / 1.44 @ 460V 60Hz
Starting current 660% (Direct on line)
Rated / Starting torque 3.73 Nm / 250%
Power factor .83/ .77 @ 1 / .75 Full Load
Efficiency IE2
SPECIFICATIONS
Specs IEC 60034
Type Test cert required
ECDec=WEG Equipamentos Elétricos SA EC Declaration
of Conformity 02-2010
REV DESCRIPTION DATE ISS'D BY APP'D
A First issue IE2. 28 Mar 2011 WC WC

B Was aluminium, now cast iron 17 Jul 2012 WC WC
C Max size was 310mm.. 20 Aug 2012 WC WC
D Starting current mod per customer info. 07 Nov 2012 WC WC
E New spec sheet data per maker info. 04 Dec 2012 WC WC

Instruction Manual For Thermo Probe - Rev.1

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DOCUMENT SUBMISSION STATUS: FOR INFORMATION

1 22.06.2018 FOR INFORMATION J.S.CHOI T.G.LEE S.I.HONG

SONG HAU 1 THERMAL POWER PLANT (2x600MW)

OWNER OWNER’S CONSULTANT

EPC CONTRACTOR EPC CONTRACTOR’S CONSULTANT

VIETNAM MACHINERY INSTALLATION TOKYO ELECTRIC POWER SERVICES

DATE NAME SIGN DOCUMENT TITLE

PREPARED 22.06.2018 J.S.CHOI

APPROVED 22.06.2018 S.I.HONG

DOCUMENT NO. REV.

Diamond Power Specialty Limited

 +44 1389 727 900

 +44 1389 757 405 (fax)

 Diamond Power Speciality Ltd

ELECTRICAL SAFETY WARNING

Rev 1.0 Page 2 of 57

Rev 1.0 Page 3 of 57

8. RECOMMENDED SPARES LIST .................................................................................................57

Rev 1.0 Page 4 of 57

1.1 Contract Identification

End User Site Song Hau 1 Power Plant

--- B78963 2 P2HBK10CT001

Customer Order No. 2016024277

Rev Description Date By

Rev 1.0 Page 5 of 57

2.2 Thermoprobe Identification

2.3 Operating Cycle

Rev 1.0 Page 6 of 57

Keep clear and be aware of the following:-

Do not operate the Thermoprobe locally unless permitted to do so.

Refer to Thermoprobe Wiring Diagram for a detailed layout of controls.

Rev 1.0 Page 7 of 57

Beam Roller Assembly

3.3 Front Roller Support Assembly

Front Roller Support Assembly

Front Bulkhead Negative Pressure Wallbox

Support Roller Roller Mounting Bracket

Rev 1.0 Page 8 of 57

Wallbox – Negative Pressure

Spring Assembly Support Pin

3.5 Rear Support

Adjustable Rear Support

Rev 1.0 Page 9 of 57

Limit Switch Probe

Rev 1.0 Page 10 of 57

Electric Drive Motor

Energy Chain Operation

Carriage Limit Switch

Rev 1.0 Page 11 of 57

Limit Switch Operation

Limit Switch Trip Plate

A typical limit switch assembly is shown below.

Limit Switch Assembly

Rev 1.0 Page 12 of 57

Gap Junction Box

Front Operating Limit Switch

Rev 1.0 Page 13 of 57

Rev 1.0 Page 14 of 57

The system is controlled from main control system by signals.

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Typical Slinging Arrangement.

Lifting in unsupported area danger.

Do NOT sling around beam