ABB Navigator 550 Use and care manual

Information INF13/114–EN
Navigator 550
Hydrazine wet-section
Spares replacement procedures
1 Safety 2 Tools required
Pozidrive screwdriver
Slot-head terminal screwdriver
Anti-static strap.
3 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/AHM550-EN) for
calibration instructions.
Dispose of the old components in accordance with the
guidelines contained in the Operating instructions
(OI/AHM550-EN).
Fig. 3.1 Low level dissolved oxygen wet-section – replacement procedures
Modbus cable assembly –
see Section 3.1, page 2
PCB housing seals,
PCB cover and PCB –
see Section 3.1, page 2
Flowmeter assembly
and flowmeter cable –
see Section 3.2, page 2
Constant-head
assembly, pressure
switch assembly and
pressure switch cable –
see Section 3.4, page 3
Solenoid valve assembly
and solenoid valve cable –
see Section 3.4, page 3

3 Replacement procedures
2 INF13/114–EN | Navigator 550 | Hydrazine wet-section | Spares replacement procedures
3.1 Replacing the PCB housing seals, PCB cover and PCB
Part numbers:
PCB housing seals: AW503 051
PCB cover: AW503 052
PCB: AW503 050
Referring to Fig. 3.2:
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. 3.3 and Table 3.1 for terminal connection details:
9. Make cable connections at the new PCB.
Referring to Fig. 3.2:
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.
3.2 Replacing the flowmeter assembly and flowmeter cable
Part numbers:
Flowmeter: AW503 068
Flowmeter cable: AW503 086
Referring to Fig. 3.4:
1. Disconnect the flowmeter cable Afrom the flowmeter B.
remove the sample inlet tubing Cfrom the flowmeter inlet
spigot D. If replacing cable(s), refer to Section 3.1 for cable
disconnection details and remove / discard the cable.
2. Disconnect the flowmeter Bfrom the QD connector E
above the flowmeter by pressing the ring and pulling the
flowmeter away.
3. Fit the new flowmeter / cable in the reverse order of removal.
Fig. 3.2 Replacing the PCB housing seals, PCB cover and PCB
Fig. 3.3 Wet section PCB cable entries
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
5
1
Additional 'daisy-chain'
cable connections
Entry Cable Color Terminal Description
1
Serial (Modbus) – refer to
Operating Instructions
(OI/AHM550-EN) for
multiple wet-section
setup.
Red
Black
Green
White
Screen
R
B
G
W
SCR
24 V
0V
Data +ve
Data –ve
Screen
2Sensor block
Blue
Red
Black
Yellow
31
32
33
35
+ve
–ve
Pt1000
Pt1000
3Pressure switch Red
Black
25
26
N/A
N/A
4Calibration
valve
Red
Black
9
10
+ve
–ve
5Flowmeter (if fitted)
Red
Brown
Black
13
15
17
+ve
GND
–ve
Table 3.1 Wet-section cable terminal connections
Fig. 3.4 Replacing the flowmeter assembly and flowmeter cable

3 Replacement procedures
Navigator 550 | Hydrazine wet-section| Spares replacement procedures | INF13/114–EN 3
3.3 Replacing the constant-head assembly, pressure switch
assembly and pressure switch cable
Part numbers:
Constant-head assembly: AW503 075
Pressure switch assembly: AW503 077
Pressure switch cable: AW503 085
Referring to Fig. 3.5:
1. Remove all tubing Ato the constant-head assembly.
2. Carefully disconnect the 2 spade connectors Bat the rear
of pressure switch C. If replacing the cable, refer to Section
3.1, page 2, for cable connection details and remove /
discard the cable.
3. Unscrew the 2 securing screws Don the upper faces of the
constant head body support arms Eand remove the
constant-head assembly complete with pressure switch.
4. If replacing the pressure switch, unscrew the 4 retaining
screws F(note that the nuts Gare constrained in the
support bracket and may fall out when screws are removed).
5. Fit a replacement pressure switch and new O-ring Hin the
reverse order of removal – note the orientation (LOW) is
always uppermost.
6. If replacing the cable, fit in the reverse order of removal and
connect the 2 spade connectors Bto the rear of the
pressure switch, otherwise re-connect the existing spade
connectors.
7. Secure the constant-head assembly, complete with pressure
switch, in the reverse order of removal.
3.4 Replacing the solenoid valve assembly and solenoid
valve cable
Part numbers:
Solenoid valve assembly: AW503 053
Solenoid valve cable: AW503 080
Referring to Fig. 3.6:
1. Remove all tubing connected to the valve A.
2. Unclip the valve cable connector Bfrom the valve body. If
replacing cable(s), refer to Section 3.1 for cable connection
details and remove / discard the cable.
3. Unscrew the 2 retaining screws Cthat hold the plate Dto
the bracket Eand withdraw the valve assembly Aand
plate D.
4. Unscrew the 2 valve securing screws and nuts Fand
remove the valve.
5. Ensure the valve cable connector is facing downwards and fit
the new valve assembly to the plate Dusing the 2 valve
securing screws and nuts F.
6. Refit the plate Dto the bracket Eusing the 2 retaining
screws C.
7. If replacing the cable, fit in the reverse order of removal and
re-clip the cable connector Bto the underside of the new
valve body.
8. Reconnect all tubing to the new valve.
Fig. 3.5 Replacing the constant-head assembly, pressure switch assembly
and pressure switch cable
Fig. 3.6 Replacing the solenoid valve assembly and solenoid valve cable
IN/OUT

For more information please contact:
INF13/114–EN 05.2013
3.5 Replacing the Modbus cable assembly
Modbus cable part numbers:
AW503 090 / 1.5 m (4.9 ft.)
AW503 091/5m(16.4 ft.)
AW503 092 / 10 m (32.8 ft.)
AW503 093 / 20 m (65.6 ft.)
Referring to Section 3.2, page 2:
1. Remove the wet-section PCB cover.
Referring to Fig. 3.7:
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. 3.7 Replacing the Modbus cable assembly
B R SCR
G W
Note
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Copyright© 2013 ABB
All rights reserved
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