Ametek Land Millwatch User manual

Millwatch / Silowatch
(CO single stream, including high-CO)
Silowatch
(CO + O2single stream)
© Land Instruments International, 2017
User Guide
Issue 12
04 September 2017
Publication Nº 802767
Language: English

Health and Safety Information
Read all of the instructions in this booklet - including all the WARNINGS and CAUTIONS
- before using this product. If there is any instruction which you do not understand, DO
NOT USE THE PRODUCT.
Safety Signs
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or
personal injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, could result in minor or
moderate injury to the user or users, or result in damage to the product or to property.
NOTE
Indicates a potentially hazardous situation which, if not avoided, could result in damage or the loss of
data.
Signs and Symbols used on equipment and Documentation
Caution, risk of electric shock.
Caution, attention to possibility of risk of damage to the product, process or surroundings. Refer
to instruction manual.
Caution, hot surface.
Protective Conductor Terminal.
Observe precautions for handling electrostatic discharge sensitive devices.
Equipment Operation
Use of this instrument in a manner not specied by Land Instruments International may be hazardous.
Read and understand the user documentation supplied before installing and operating the equipment.
The safety of any system incorporating this equipment is the responsibility of the assembler.
Protective Clothing, Face and Eye Protection
It is possible that this equipment is to be installed on, or near to, machinery or equipment operating at
high temperatures and high pressures. Suitable protective clothing, along with face and eye protection
must be worn. Refer to the health and safety guidelines for the machinery/equipment before installing
this product. If in doubt, contact Land Instruments International.
Electrical Power Supply
Before working on the electrical connections, all of the electrical power lines to the equipment must
be isolated. All the electrical cables and signal cables must be connected exactly as indicated in these
operating instructions. If in doubt, contact Land Instruments International.
Storage
The instrument should be stored in its packaging, in a dry sheltered area.
Unpacking
Check all packages for external signs of damage. Check the contents against the packing note.
Lifting Instructions
Where items are too heavy to be lifted manually, use suitably rated lifting equipment. Refer to the
Technical Specication for weights. All lifting should be done as stated in local regulations.
IMPORTANT INFORMATION - PLEASE READ

Health and Safety Information
Read all of the instructions in this booklet - including all the WARNINGS and CAUTIONS
- before using this product. If there is any instruction which you do not understand, DO
NOT USE THE PRODUCT.
Safety Signs
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or
personal injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, could result in minor or
moderate injury to the user or users, or result in damage to the product or to property.
NOTE
Indicates a potentially hazardous situation which, if not avoided, could result in damage or the loss of
data.
Signs and Symbols used on equipment and Documentation
Caution, risk of electric shock.
Caution, attention to possibility of risk of damage to the product, process or surroundings. Refer
to instruction manual.
Caution, hot surface.
Protective Conductor Terminal.
Observe precautions for handling electrostatic discharge sensitive devices.
Equipment Operation
Use of this instrument in a manner not specied by Land Instruments International may be hazardous.
Read and understand the user documentation supplied before installing and operating the equipment.
The safety of any system incorporating this equipment is the responsibility of the assembler.
Protective Clothing, Face and Eye Protection
It is possible that this equipment is to be installed on, or near to, machinery or equipment operating at
high temperatures and high pressures. Suitable protective clothing, along with face and eye protection
must be worn. Refer to the health and safety guidelines for the machinery/equipment before installing
this product. If in doubt, contact Land Instruments International.
Electrical Power Supply
Before working on the electrical connections, all of the electrical power lines to the equipment must
be isolated. All the electrical cables and signal cables must be connected exactly as indicated in these
operating instructions. If in doubt, contact Land Instruments International.
Storage
The instrument should be stored in its packaging, in a dry sheltered area.
Unpacking
Check all packages for external signs of damage. Check the contents against the packing note.
Lifting Instructions
Where items are too heavy to be lifted manually, use suitably rated lifting equipment. Refer to the
Technical Specication for weights. All lifting should be done as stated in local regulations.
IMPORTANT INFORMATION - PLEASE READ
Contact Us
UK - Droneld
Land Instruments International
Tel: [phone]
Email: [email protected]
Web: www.landinst.com
USA - Pittsburgh
AMETEK Land, Inc.
Tel: [phone]
Email: [email protected]
Web: www.ametek-land.com
China
AMETEK Land China Service
Tel: [phone] ext 122
Email: [email protected]
Web: www.landinst.com
India
AMETEK Land India Service
Tel: +91 - 80 67823240
Email: [email protected]
Web: www.landinst.com
For further details on all AMETEK Land oces, distributors and representatives, please visit
our websites.
Return of Damaged Goods
IMPORTANT If any item has been damaged in transit, this should be reported to the carrier and to the
supplier immediately. Damage caused in transit is the responsibility of the carrier not the supplier.
DO NOT RETURN a damaged instrument to the sender as the carrier will not then consider a claim. Save
the packing with the damaged article for inspection by the carrier.
Return of Goods for Repair
If you need to return goods for repair please contact our Customer Service Department. They will be able
to advise you on the correct returns procedure.
Any item returned to Land Instruments International should be adequately packaged to prevent damage
during transit.
You must include a written report of the problem together with your own name and contact information,
address, telephone number, email address etc.
Design and Manufacturing Standards
The Quality Management System of Land Instruments International is approved to BS EN ISO 9001 for
the design, manufacture and on-site servicing of combustion, environmental monitoring and non-contact
temperature measuring instrumentation.
Approvals apply in the USA
Operation of radio transmitters, telephones or other electrical/electronic devices in close proximity
to the equipment while the enclosure doors of the instrument or its peripherals are open, may cause
interference and possible failure where the radiated emissions exceed the EMC directive.
The protection provided by this product may be invalidated if alterations or additions are made to the
structural, electrical, mechanical or pneumatic parts of this system. Such changes may also invalidate the
standard terms of warranty.
Copyright
This manual is provided as an aid to owners of Land Instruments International’s products and contains
information proprietary to Land Instruments International. This manual may not, in whole or part, be
copied, or reproduced without the expressed written consent of Land Instruments International Ltd.
Copyright © 2016 Land Instruments International.
MARCOM0311, Issue 7, 01 November 2016
Approvals apply in India

User Guide Millwatch/Silowatch
Single Stream
Contents
1 General Description 1
2 Installation Dos and Don'ts 2
3 Service Requirements 3
4 Diagram of Monitor 4
5 Connecting the Electrical Power Supply 5
5.1 Connecting the Autocal Unit*
*Millwatch / Silowatch (CO single stream, including high-CO) 6
6 Probe Dimensions and Mounting Flange Details 7
6.1 Coal Mill Probe Abrasive Applications 7
6.2 Standard Probe Non Abrasive Applications 8
7 Recommended Installation for Probe 9
7.1 Recommendations for Installing the Instrument Air Supply and
Calibration Gas 9
7.2 Connecting the Probe 10
8 Installing the Antifreeze Line 11
8.1 Connecting the Antifreeze Line 12
9 Blow-back Unit 13
9.1 Blow-back unit with antifreeze line 13
9.2 Blow-back unit with standard line 13
10 Connecting the Blow-back Trigger 14
11 Input Connection to Trigger Standby 15
12 Electrical and Signal Connections 16
12.1 Summary of Connections
Millwatch / Silowatch (CO single stream, including High-CO) 17
12.2 Summary of Connections
Silowatch (CO & O2single stream) 18
13 Digital Inputs and Outputs 19
14 Analogue Outputs 20
15 Description of the Control Panel 21

User GuideMillwatch/Silowatch
Single Stream
16 Warm Up Routine 22
17 Essential Setup Procedures 23
17.1 The Entry Code 23
17.2 Set the Time and Date 23
17.3 Set the Alarm Levels 23
17.4 Selecting an appropriate alarm level. 23
17.5 Select the Units of Measurement 24
17.6 Set the Automatic Calibration Times and Calibration
Gas Concentrations 24
18 Diagnostics 25
18.1 Fault Messages 25
18.2 Clearing Faults 26
18.3 Key to Menu Items 26
18.3.2 Menu options - Silowatch (CO & O2 single stream) 27
19 TechnicalSpecication 28
20 Spare Parts 29
20.1 Location of Spares 30
20.2 System Flow Diagrams 31
21 Calibration 33
21.1 Automatic Calibration - Quick Start 33
22 Preventative Maintenance 34
22.1 Maintenance Relay 34
22.2 Changing the Peristaltic Pump Tube 34
22.3 Replacing the Pump Head 35
22.4 Replacing the pump diaphragm 317.552 35
22.5 Changing a Sensor Unit 35
Appendix 1 Parameter Record Sheets

Page 1
Millwatch/Silowatch
Single Stream
User Guide
1 General Description
This User Guide gives instructions on how to install, operate and maintain the
following instruments:
• Millwatch / Silowatch (CO single stream, including High-CO)
• Silowatch (CO + O2single stream)
Each instrument is an extractive gas analyser designed to monitor carbon
monoxide (CO) levels in coal pulverizing mills, hoppers and storage silos. The
Silowatch also monitors Oxygen (O2) levels.
Carbon monoxide is produced by incomplete or spontaneous combustion and its
presencecangiveadvancedwarningofare.
There are two types of sample probe available, one sample probe has a hardened
protective cover designed for highly abrasive pulverised coal.
A continuous sample of gas is drawn into the analyser via sample probes and
lines.
The sample gas is conditioned within the analyser and then analysed by dual
sensors which operate alternately to improve sensor life and accuracy, whilst also
providing a vital self checking function.
To prevent blockages the probe is automatically purged with compressed air at
preset intervals.
WARNING
The Millwatch and Silowatch are not designed for use in hazardous
areas.
The Millwatch and Silowatch are intended as an early warning
device.Itisnotasubstituteforacertiedredetectionsystem.

Millwatch/Silowatch
Single Stream
User Guide
Page 2
2 Installation Dos and Don'ts
WARNING
Isolate the electricity supply before starting work.
WARNING
The Millwatch/Silowatch Detector is permanently connected to an electricity
supply.
An external switch or circuit breaker is required. An external over current
protection device must be provided as close to the monitor as possible.
Please read and follow these instructions carefully.
The Detector is not designed to be used in conjunction with any equipment unless
speciedbyLAND.TheDetectorandprobemustnotbeconnectedtoanyother
devices. The protection provided by the equipment may be impaired if it is not used in
themannerspeciedinthisdocument.
DO DON'T
Provide a working platform with access for
installation and servicing.
Install the probe and Detector as
described in this document.
Install the power and signal lines in
accordance with local regulations.
Provide all of the services as stated in the
technicalspecication.
Remove exhaust gas and condensate to a
safe area.
Keep the Detector door closed.
Mount vertically on a dry, clean surface.
Mountuprightwiththettingsatthe
bottom.
Use all four of the mounting brackets.
Providecertiedcalibrationgas.
Purge and leak test the calibration gas
pipework before use. Calibration gas is
expensive!
Installthemillprobeattheclassier
outlet,wherethereisapredictableow
direction
Do: Install the mill probe with the
abrasionshieldfacingtheowof
pulverized coal
Install where there is excessive vibration.
Mount the Detector more than 15 m (50
feet) from the probe, as this will increase
the response time.
Loop the sample line, this will cause
condensate to collect.
Install the Detector in areas of extreme
temperature.Seetechnicalspecication.
Installtheangemorethan75mm(3in)
from the extraction point.
Exceed the maximum probe temperature.
Seetechnicalspecication.
Site the analyser where the ambient
temperature is less than 0 ºC (32 ºF) or
greater than 45 ºC (113 ºF).
The probe must be situated where the
temperature will not exceed the rating of
the sample line. Unless cabinet heaters
or coolers are provided.
Installtheprobewheretheltercanbe
eroded by coal dust.
NOTE
You must install the peristaltic pump tube. It has been removed for transportation
and storage.
See Preventative Maintenance.

Page 3
Millwatch/Silowatch
Single Stream
User Guide
3 Service Requirements
Service Requirement Size/Specication
1 Calibration gas* 1 to 2 bar (15 to 30 psi)
CO in Nitrogen
20 litres (0.7ft3)
4 l/min (0.15 ft3/min)
during calibration
1/4 in outside diameter
PTFE, nylon or stainless
steel tube
2 Instrument air* 1 to 2 bar (15 to 30 psi)
dry. regulated, clean, oil
free compressed or bottled
air
1/4 in outside diameter
PTFE, nylon or stainless
steel tube
3 Condensate removal Optional 1/2 in NPT - 14 female
route to collection device
4 Electrical power supply+83 to 132 V or
165 to 264 V a.c.
50 to 60 Hz 300 W
Cable 3 way
Core size 24/0.2 minimum
5 Cooling air 4 bar (60 psi) minimum
8 bar (120 psi maximum)
Clean. Oil-free
300 l/min (10 ft3/min)
1/4 in outside diameter
PTFE, nylon or stainless
steel tube
6 Sample line connection 15 m (50 ft) maximum
nylon/antifreeze
Outside diameter 1/4 in
Sampleowrateis
1.5 l/min (0.05 ft/min)
7 Exhaust
Must be kept at atmospheric
pressure.
Do not allow back pressure
Optional 3/16inbarbedttingfor
4.7 mm inside diameter
tubing. Vent to safe area.
8 Cable glands Customer's connections Cable diameter 7 to 10.5
mm (0.58 to 0.41 in)
9 Calibration gas to probe 15 m (50 ft) maximum
nylon/antifreeze
1/4 in outside diameter
PTFE, nylon or stainless
steel tube
10 Blow-back air 4 to 8 bar (60 to 120 psi) 1/4 in outside diameter
PTFE, nylon or stainless
steel tube
* these MUST be set to the same pressure
+electricalpowersupplyconnectedtoterminalrail,wheretted

Millwatch/Silowatch
Single Stream
User Guide
Page 4
4 Diagram of Monitor
Weight: 53 kg (117 lb)
1 Instrument air
2 Calibration gas
3 Condensate removal
4 Cable glands
5 Cooling air
6 Sample line connection
Note blow-back air is supplied directly to the blow-back unit.

Page 5
Millwatch/Silowatch
Single Stream
User Guide
5 Connecting the Electrical Power Supply
Where no case heater or antifreeze line are used, the power supply is connected
using the plug supplied with the instrument.
Where a case heater and/or antifreeze line are used, the power supply is
connected on the terminal rail.
L Live Brown
N Neutral Blue
Earth (Ground) Green/yellow
Whenanantifreezelineand/orcaseheateristtedthepowersupplymustbe
connected on the terminal rail.
On/Off
Check the fuse is installed correctly.
The arrow showing the correct voltage
should be aligned with the white bar.
A plug is provided with the instrument.

Millwatch/Silowatch
Single Stream
User Guide
Page 6
5.1 Connecting the Autocal Unit*
*Millwatch / Silowatch (CO single stream, including high-CO)
Nº Description
1 Not used
2 Instrument air (for calibration)
3 Not used
4 CO calibration gas
5 Not used
6 Not used
7 High-range CO calibration gas
8 Condensate drain (½” - 14 NPT Thread)
9 Cable glands
10 Safety pressure exit
11 Not used
12 By-pass gas exhaust (Red channel)
13 By-pass gas exhaust (Blue channel)
14 Sample gas exhaust (Blue channel)
15 Sample gas exhaust (Red channel)
16 Ambient air inlet
17 Blanking plug

Page 7
Millwatch/Silowatch
Single Stream
User Guide
6 Probe Dimensions and Mounting Flange Details
6.1 Coal Mill Probe Abrasive Applications
099.392 0.5mprobeandmountingange
321.006 Filter
321.005 Abrasion shield
Typical installation of Mill
ProbeinaClassierOutlet

Millwatch/Silowatch
Single Stream
User Guide
Page 8
6.2 Standard Probe Non Abrasive Applications
Part Nº Probe length
704.424 500 mm
702.759 1000 mm

Page 9
Millwatch/Silowatch
Single Stream
User Guide
7.1 Recommendations for Installing the Instrument Air Supply and
Calibration Gas
*A 30 psi pressure regulator is supplied in the spares kit with the monitor and
mustbettedbytheuser.Allotherpressureregulatorsandpipeworkmustbe
supplied by the customer.
7 Recommended Installation for Probe
Position the analyser and probe below the blowback unit to allow any condensate
to drain.
1 Cooling air supply
2* Calibration air supply
3 Compressed air supply
4 Mill/Silo Fire Detector
5 Calibration gas (CO), 2
stage non-relieving pressure
regulator
Millwatch / Silowatch (CO single stream, including high-CO) only

Millwatch/Silowatch
Single Stream
User Guide
Page 10
7.2 Connecting the Probe
1 Sample gas
2 Calibration gas
3 Compressed air
4 Alternative entry for antifreeze line
An alternative probe is available for non-abrasive
applications.
All installations have the probe blow-back
facility, however the probe type is optional.
In hazardous areas, the blow-back valve is
located within the analyzer.

Page 11
Millwatch/Silowatch
Single Stream
User Guide
8 Installing the Antifreeze Line
Only two of the pipes in the antifreeze line are used. Make sure you identify
these AT BOTH ENDS of the line.
The power supply connects to the circuit breaker INSIDE the Mill/Silo Fire
Detector.
A Signal Cables (black, red, brown) use to connect blowback solenoid valve
B Sample and calibration gas lines (one is not used) identify lines at both ends
C Power Supply (brown, blue, green/yellow)
D Thermocouple NOT USED (make safe)
E Nut
F Washer
Part Nº Description
323.512 Antifreeze sample line 230 V
323.513 Antifreeze sample line 110 V
Alternative sample line designs are used in the USA.

Millwatch/Silowatch
Single Stream
User Guide
Page 12
8.1 Connecting the Antifreeze Line
Connections viewed from the inside of the analyser.
Note: Plugsarettedtotheoutsideofthecasewhenanti-freezelinesareused.

Page 13
Millwatch/Silowatch
Single Stream
User Guide
1 Sample gas from probe
2 Calibration gas to probe
3 Antifreeze line, sample gas to monitor
4 Antifreeze line, calibration gas from monitor
5 Compressed air (60 to 120 psi, 4 to 8 bar)
6 Blowback trigger from monitor (it is
possible to use the signal cable in the
antifreeze line, as shown in diagram)
7 Cable gland (alternative connection for
blow-back trigger from monitor)
9 Blow-back Unit
In hazardous areas, the blowback valve is located within the analyzer.
9.1 Blow-back unit with antifreeze line
Do not adjust the regulator.
9.2 Blow-back unit with standard line
Do not adjust the regulator.
1 Sample gas from probe
2 Calibration gas to probe
3 Sample gas to monitor
4 Calibration gas from monitor
5 Compressed air (60 to 120 psi, 4 to 8 bar)
6 Blowback trigger from monitor

Millwatch/Silowatch
Single Stream
User Guide
Page 14
10 Connecting the Blow-back Trigger
Connect the blow-back unit to Conn 21.
Service Requirement Size/Specication
1 Blow-back trigger CONN 21 Pin 1 (0 V dc)
CONN 21 Pin 2 (24 V dc)
Blowback unit Pin 1
Blowback unit Pin 2