ABB Navigator 550 Use and care manual

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ABB MEASUREMENT & ANALYTICS | INFORMATION | INF12/113-EN REV. C
Navigator 550
Low level dissolved oxygen wet-section
Spares replacement procedures
Measurement made easy
1 Introduction
These procedures must be carried out by a trained
technician.
Tools required
• Pozidrive screwdriver
• Slot-head terminal screwdriver
• Anti-static strap.
2 For more information
Further information is available from:
www.abb.com/analytical
or by scanning these codes:
Sales Service
Navigator 550
low level dissolved
oxygen wet-section

3 Safety
2 INF12/113–EN Rev. C | Navigator 550 | Low level dissolved oxygen wet-section | Spares replacement procedures
3 Safety 4 Replacement procedures
Warning.
These procedures must be carried out by a trained technician.
CHEMICAL
Ensure personal protective equipment (PPE) such as
gloves and eye protection are worn during any
maintenance.
Observe all health and safety procedures for handling
chemicals.
To familiarize yourself with handling precautions, dangers
and emergency procedures, always review the Material
Safety Data Sheets prior to handling containers,
reservoirs and delivery systems that contain chemical
reagents and standards.
Take care if cleaning any spillages and observe all relevant
safety instructions. Wipe up any spillages using clean
water.
Perform general cleaning of the wet-section using a damp
cloth only – mild detergent can be used as a cleaning aid.
Do not use Acetone or any organic solvents.
ELECTRICAL
Isolate all high voltage supplies to the transmitter before
performing replacement procedures.
The wet-section is vulnerable to electrostatic damage.
Wear an anti-static strap or dismantle the wet-section on
an anti-static workbench.
Ensure all electrical connections are kept dry at all times.
GENERAL
Shut off the external sample supply to the wet-section
before performing replacement procedures. When a
procedure is complete, restore power to the transmitter,
sample to the wet-section at the correct flow rate and, if
necessary, calibrate the wet-section – refer to the
wet-section Operating Instructions (OI/ADS550-EN) for
calibration instructions.
Dispose of the old components in accordance with the
guidelines contained in the Operating instructions
(OI/ADS550-EN).
Fig. 4.1 Low level dissolved oxygen wet-section – replacement procedures
Modbus cable assembly –
see Section 4.5, page 5 PCB housing O-rings,
PCB cover and PCB
see Section 4.1, page 3
Tundish assembly –
see Section 4.2, page 3
Flowmeter assembly –
see Section 4.3, page 4
Drain valve assembly
and drain valve cable –
see Section 4.4, page 4

4 Replacement procedures
Navigator 550 | Low level dissolved oxygen wet-section | Spares replacement procedures | INF12/113–EN Rev. C 3
4.1 Replacing the PCB housing seals, PCB cover and PCB
Part numbers:
PCB housing seals: AW502 051
PCB cover: AW502 052
PCB: AW502 050
Referring to Fig. 4.2:
1. Remove and retain the 4 PCB cover fixing screws and
washers Aand remove the PCB cover B.
2. If replacing PCB housing seals, remove and discard housing
seal C.
3. Disconnect all cables from the PCB D, loosen all cable
glands and remove cables.
4. Remove and retain the 4 PCB housing fixing screws and
washers Eand remove the PCB housing F.
5. If replacing PCB housing seals, lift PCB housing seal Gout
of the groove and discard.
6. Remove and retain the 2 PCB fixing screws and washers H
and remove the PCB D. If replacing PCB housing seals, fit
the new (large) PCB housing seal Gin the groove (a small
amount of silicone sealant or grease can be used to help
retain the seal in place).
7. Fit the new PCB to the rear of the main case using the 2 PCB
retaining screws and washers H.
8. Refit the PCB housing Eusing the 4 PCB housing fixing
screws and washers D.
Referring to Fig. 4.3 and Table 4.1 for terminal connection details:
9. Make cable connections at the new PCB.
Referring to Fig. 4.2:
10. If replacing PCB housing seals, fit the new (small) PCB
housing seal Cbetween the PCB cover Band PCB
housing F(a small amount of silicone sealant or grease can
be used to help retain the seal in place).
11. Refit the PCB cover Busing the 4 PCB cover fixing screws
and washers A, ensuring PCB housing seal Cis located
correctly in its groove.
4.2 Replacing the tundish assembly
Part number: AW502 065
Referring to Fig. 4.4:
1. Rotate the sample outlet tube Auntil the open end is free of
the tundish assembly B.
2. Disconnect the drain tube Cfrom the tundish assembly B.
3. Unscrew and remove the 2 tundish retaining screws D
taking care to retain the spacers Elocated between the rear
of the tundish assembly and the main case.
4. Remove the old tundish assembly Band fit the new tundish
assembly in the reverse order of removal.
Fig. 4.2 Replacing the PCB housing seals, PCB cover and PCB
Fig. 4.3 Wet section PCB cable entries
Entry Cable Color Terminal Description
1
Serial (Modbus) – refer
Operating Instructions
(OI/ADS550-EN) for
multiple wet-section
setup.
Red
Black
Green
White
Screen
R
B
G
W
SCR
24 V
0V
Data +ve
Data –ve
Screen
2Drain valve Red
Black
9
10
+ve
–ve
3Flowmeter (if fitted)
Red
Brown
Black
13
15
17
+ve
GND
–ve
4Sensor block
Blue
Red
Black
Yellow
31
32
33
35
+ve
–ve
Pt1000
Pt1000
Table 4.1 Wet-section cable terminal connections
Fig. 4.4 Replacing the tundish assembly
B R Scr
G W
1 3 5 7 9 1 1 13 15 17 19 21 23 25 27 29 31 33 3
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
23 4
1
Additional 'daisy-chain'
cable connections

4 Replacement procedures
4 INF12/113–EN Rev. C | Navigator 550 | Low level dissolved oxygen wet-section | Spares replacement procedures
4.3 Replacing the flowmeter assembly
Part number: AW502 060
Flowmeter assembly: AW502 060
Referring to Fig. 4.6:
1. Depress the manual override button Aon the drain valve
assembly to drain the wet-section.
2. Remove the wet-section PCB cover as detailed in step 1 of
Section 4.1, page 3.
Referring to Fig. 4.5:
3. Loosen cable gland Aat the wet-section PCB housing B.
4. Disconnect the flowmeter cable Cfrom wet-section PCB
terminals 13 (red, +ve), 15 (brown, GND) and 17 (black –ve) –
see Fig. 4.3, page 3 and remove cable.
5. Depress the QD coupling collar Don QD coupling Eand
lift the top QD coupling Ecomplete with sample outlet tube
Faway from the flowmeter G.
6. Depress the QD coupling collar Jon QD coupling Kand
lift the flowmeter away.
7. Fit the replacement flowmeter into the QD coupling Kand
refit QD coupling Eto the flowmeter outlet.
8. Pass the flowmeter cable through the cable gland Aat the
wet-section PCB housing Band terminal connections to
PCB terminals 13 (red, +ve), 15 (brown, GND) and 17 (black
–ve) – see Fig. 4.3, page 3.
9. Refit the PCB cover as detailed in step 11, Section 4.1,
page 3.
10. Ensure the sample outlet tube Fis located correctly in the
tundish assembly I.
4.4 Replacing the drain valve assembly
and drain valve cable assembly
Part numbers:
Drain valve assembly: AW502 056
Drain valve cable assembly: AW502 085
Referring to Fig. 4.6:
1. Depress the manual override button Aon the drain valve B
to drain the wet-section.
2. Disconnect the clip-on cable connector Cfrom the end of
the drain valve coil housing by depressing the clip D.
3. Disconnect the drain tube from the barbed outlet connector
Eon the bottom of the drain valve B.
4. Lock hex coupling Gand rotate nut Hclockwise to release
couplings. Remove the valve assembly, complete with
coupling G. Remove coupling Gfrom the valve assembly
and fit to new valve, complete with new bonded seal I.
5. If fitting a new drain valve cable assembly, remove the
wet-section cover as detailed in step 1 of Section 4.1, page 3
and loosen the drain valve cable gland in the wet-section PCB
housing and proceed with steps 7, 8 and 9 below.
If using the existing cable, re-connect the clip-on cable
connector Cto the end of the drain valve coil housing.
6. Disconnect the drain valve cable from the terminal block – see
Fig. 4.3, page 3 and discard the cable.
7. Feed the replacement drain valve cable through the cable
gland and make connections to the black, red, screen, green
and white PCB wet-section terminals (see Fig. 4.3, page 3)
and at the transmitter (see OI/ADS550-EN).
8. Connect the drain valve clip-on cable connector Cto the
end of the drain valve coil housing.
Note. The orientation of the flow arrow on the flowmeter
must be upwards.
Fig. 4.5 Replacing the flowmeter assembly and flowmeter cable
Fig. 4.6 Replacing the drain valve assembly and drain valve cable

4 Replacement procedures
Navigator 550 | Low level dissolved oxygen wet-section | Spares replacement procedures | INF12/113–EN Rev. C 5
4.5 Replacing the Modbus cable assembly
Modbus cable part numbers:
AW502 090 / 1.5 m (4.9 ft.)
AW502 091/5m(16.4 ft.)
AW502 092 / 10 m (32.8 ft.)
AW502 093 / 20 m (65.6 ft.)
Referring to Section 4.2, page 3:
1. Remove the wet-section PCB cover.
Referring to Fig. 4.7:
2. Loosen cable gland Aat the wet-section PCB housing B
and disconnect the Modbus cable Dfrom the terminal block
connections Cmarked black, red, screen, green and white.
3. Withdraw the Modbus cable Dfrom the PCB housing and
main case assembly and discard.
4. Feed the replacement Modbus cable into the main case via
the guide channel Eat the top, feed through the gland and
remake connections to the black, red, screen, green and
white PCB wet-section terminals and at the transmitter.
5. Refit the PCB cover by reversing the removal procedure.
Fig. 4.7 Replacing the Modbus cable assembly
B R SCR
G W

Notes
6 INF12/113–EN Rev. C | Navigator 550 | Low level dissolved oxygen wet-section | Spares replacement procedures
Notes

Notes
Navigator 550 | Low level dissolved oxygen wet-section | Spares replacement procedures | INF12/113–EN Rev. C 7
Notes

INF12/113-EN Rev. B 07.2019
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We reserve the right to make technical changes or modify the contents of this document
without prior notice. With regard to purchase orders, the agreed particulars shall prevail.
ABB does not accept any responsibility whatsoever for potential errors or possible lack of
information in this document.
We reserve all rights in this document and in the subject matter and illustrations contained
therein. Any reproduction, disclosure to third parties or utilization of its contents – in
whole or in parts – is forbidden without prior written consent of ABB.
© ABB 2019 3KXA494550R2001
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