ABB - NAV 500 Sodium SWAS

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A B B M E A S U R E M E N T & A N A LY T I C S | O P E R AT I N G I N S T R U C T I O N | O I/A S O 5 5 0 - E N R E V. G
Navigator 500
Sodium analyzer
Measurement made easy
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Navigator 500 Introduction
sodium analyzer
The Navigator 500 sodium analyzer is designed to
provide continuous monitoring and control of power
station boiler feed water / steam condensate.
The analyzer comprises a Navigator 540 transmitter

with multiple wet-section capability for up to 4 wet-
sections.
This Operating Instruction provides installation,

operation and maintenance procedures for the
Navigator 550 sodium wet-section and a Navigator
540 transmitter.
For more information
Further publications for the Navigator 500 sodium analyzer are
available for free download from:
www.abb.com/measurement
or by scanning this code:
Search for or click on
Commisioning Instruction
Navigator 550 CI/ASO550-EN
Sodium wet-section
Commisioning Instruction
Navigator 540 CI/AWT540-EN
Transmitter
Navigator 500
Sodium analyzer Contents
Contents
1 Health & Safety ................................................................ 3 5 Calibration ..................................................................... 21
1.1 Safety precautions ................................................... 3 5.1 Accessing the Configuration level menus ............... 21
1.2 Potential safety hazards ........................................... 3 5.2 Performing a calibration for the first time –
1.2.1 Navigator 550 sodium wet-section – single-stream wet-section ...................................... 22
electrical ....................................................... 3 5.3 Performing a calibration for the first time –
1.2.2 Navigator 550 sodium wet-section – multi-stream wet-section ....................................... 23
chemical reagents ......................................... 3 5.4 Calibration parameters – offset and slope .............. 24
1.2.3 Navigator 540 transmitter – electrical ............ 3 5.5 Calibration options ................................................. 24
1.3 Safety standards ...................................................... 3 5.5.1 Scheduled calibration ................................. 24
1.4 Safety conventions ................................................... 4 5.5.2 Monitoring calibration progress .................. 24
1.5 Symbols ................................................................... 4 5.5.3 Abort calibration ......................................... 24
1.5.1 Navigator 550 sodium wet-section ............... 4 5.5.4 Process calibration procedure .................... 25
1.5.2 Navigator 540 transmitter ............................. 5 5.5.5 Grab sample .............................................. 28
1.6 Product recycling and disposal (Europe only) ........... 5 5.6 Calibration timings ................................................. 28
1.6.1 End-of-life battery disposal ........................... 5 5.6.1 Recovery period ......................................... 28
1.7 Restriction of Hazardous Substances (RoHS) ........... 5 5.7 Regeneration procedure ........................................ 28
2 Overview .......................................................................... 6 6 Operation overview – transmitter ................................. 29

2.1 Navigator 550 sodium wet-section ........................... 6 6.1 Front panel keys .................................................... 29
2.2 Navigator 540 transmitter ......................................... 7 6.2 Transmitter operation modes ................................. 30
6.3 Operator menus .................................................... 30
3 Installation ....................................................................... 8 6.4 Navigation overview ............................................... 31
6.5 Operating mode .................................................... 31
3.1 Installing the wet-section .......................................... 8
6.6 View mode ............................................................ 33
3.1.1 Sample requirements .................................... 8
6.7 Log mode .............................................................. 34
3.1.2 Location ....................................................... 8
6.7.1 Calibration log entries ................................. 35
3.1.3 Mounting the wet-section ............................. 9
6.8 Logging ................................................................. 36
3.1.4 Connecting the external sample lines .......... 10
6.8.1 SD card / USB stick ................................... 36
3.1.5 Connecting the reagent / calibration /
6.8.2 SD card / USB stick
regeneration tubing ..................................... 11
insertion and removal ................................. 37
3.2 Installing the transmitter ......................................... 12
6.8.3 Archive file types ........................................ 37
3.2.1 Transmitter optional accessories ................. 12
6.8.4 Data files .................................................... 37
3.2.2 Transmitter location .................................... 12
6.8.5 Log files ..................................................... 38
3.2.3 Panel mounting ........................................... 12
6.8.6 Daylight saving ........................................... 38
3.2.4 Pipe mounting ............................................ 13
6.9 Password security and Access Level ..................... 39
3.2.5 Wall mounting ............................................. 13
6.9.1 Setting passwords ..................................... 39
3.3 Multiple wet-section setup ..................................... 13
6.9.2 Access Level .............................................. 39
3.4 Electrical connections – wet-section ....................... 14
6.10 Display icons ......................................................... 40
3.4.1 Solution ground .......................................... 14
6.10.1 Diagnostic icons ........................................ 40
3.4.2 Accessing the wet-section PCB .................. 14
6.10.2 Title bar icons ............................................ 40
3.4.3 Wet-section PCB connections .................... 15
6.10.3 Log icons ................................................... 41
3.5 Electrical connections – transmitter ........................ 16
6.10.4 Status bar icons ......................................... 41
3.5.1 Accessing the transmitter
connection board ....................................... 17
3.5.2 Transmitter connections ............................. 18 7 Menu descriptions ........................................................ 42
3.5.3 Digital I/O, relays and analog output 7.1 Menu overview ...................................................... 42
connections ................................................ 18 7.1.1 Calibrate .................................................... 43
7.1.2 Sensor Setup ............................................. 46
4 Setup ............................................................................. 19 7.1.3 Device Setup .............................................. 48
7.1.4 Display ....................................................... 50
4.1 Setting-up the wet-section ..................................... 19
7.1.5 Input/Output .............................................. 52
4.1.1 Fitting the electrodes .................................. 19
7.1.6 Process Alarm ............................................ 54
4.1.2 Fitting and filling the reservoir (option) ......... 20
7.1.7 Media Card ................................................ 55
4.1.3 Sensor panel .............................................. 20
7.1.8 Communication .......................................... 56
4.2 Transmitter start-up ............................................... 20
7.1.9 Device Info ................................................. 57
7.2 Analog sources and digital input / output sources .. 58
7.2.1 Analog sources .......................................... 58
7.2.2 Digital output sources ................................ 58
7.2.3 Digital input sources ................................... 58
OI/ASO550–EN Rev. G 1
Navigator 500
Sodium analyzer Contents
8 Maintenance ..................................................................59 Appendix A – Troubleshooting ......................................... 72

8.1 Chemical solutions .................................................59 A.1 Diagnostic messages ............................................. 72
8.1.1 Reagent solutions .......................................59 A.2 Calibration pass and fail limits ................................ 75
8.1.2 Standard solutions ......................................59 A.3 Checking the temperature input ............................. 76
8.1.3 Salt bridge solution .....................................59 A.4 Incorrect or erratic flow rate readings ..................... 76
8.2 Scheduled servicing ...............................................60 A.5 Erratic sodium readings ......................................... 76
8.2.1 Weekly ........................................................60
8.2.2 Monthly .......................................................60 Appendix B – Multi-stream sodium wet-section ............. 77
8.2.3 12-Monthly .................................................61
B.1 Multi-stream with flowmeters fitted ......................... 77
8.3 Automatic regeneration ..........................................61
B.2 Multi-stream with no flowmeters fitted .................... 77
8.4 Manual regeneration ...............................................63
8.5 Shut-down procedures ...........................................63
8.5.1 Preparing the sodium and Appendix C – Multiple wet-section setup ........................ 78
reference electrodes for storage ..................64 C.1 Configuring the device address .............................. 78
8.6 Replacing plastic tubing – C.2 Serial connections .................................................. 78
multi-stream wet-sections ......................................65
8.7 Replacing plastic tubing – Appendix D – Spare parts and consumables .................. 79
single-stream wet-sections .....................................67 D.1 Navigator 500 sodium consumables ...................... 79
D.2 Navigator 500 sodium wet-section spares ............. 79
9 Specification – analyzer ................................................69 D.3 Navigator 540 transmitter ....................................... 84
10 Specification – transmitter ............................................70
11 Specification – wet-section ..........................................71
2 OI/ASO550–EN Rev. G
Navigator 500
Sodium analyzer 1 Health & Safety
1 Health & Safety

1.1 Safety precautions
Be sure to read, understand and follow the instructions contained within this manual before and during use of the equipment. Failure
to do so could result in bodily harm or damage to the equipment.
Warning. Installation, operation, maintenance and servicing must be performed:

 by suitably trained personnel only
 in accordance with the information provided in this manual
 in accordance with relevant local regulations
1.2 Potential safety hazards

1.2.1 Navigator 550 sodium wet-section – electrical
The Navigator 550 sodium wet-section operates on 24V DC supplied from the transmitter.
There are no hazardous voltages present.
1.2.2 Navigator 550 sodium wet-section – chemical reagents
Warning. To ensure safe use when handling chemicals, the following points must be observed:
 Review the Material Safety Data Sheets prior to handling containers, reservoirs, and delivery systems that contain chemical
reagents and standards.
 Protective eye wear and hand wear must always be used when contact with chemicals is possible.
 Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of
high pressure and / or temperature.
 Chemicals must be stored away from heat, protected from temperature extremes and powders kept dry.
 When disposing of chemicals ensure that no two chemicals are mixed.
Safety advice concerning the use of the equipment described in this manual or any relevant Material Safety Data Sheets (where
applicable) may be obtained from the Company, together with servicing and spares information.
1.2.3 Navigator 540 transmitter – electrical
Warning. To ensure safe use when operating this equipment, the following points must be observed:
 Up to 240V AC may be present. Be sure to isolate the supply before removing the terminal cover.
 Normal safety precautions must be taken to avoid the possibility of an accident occurring when operating in conditions of
high pressure and / or temperature.
Safety advice concerning the use of the equipment described in this manual or any relevant Material Safety Data Sheets (where
applicable) may be obtained from the Company, together with servicing and spares information.
1.3 Safety standards

This product has been designed to satisfy the requirements of IEC61010-1:2010 3rd edition 'Safety Requirements for Electrical
Equipment for Measurement, Control and Laboratory Use' and complies with US NEC 500, NIST and OSHA.
Navigator 500
1.4 Safety conventions
Warning. In this manual, a warning is used to indicate a condition which, if not met, could cause serious personal injury and / or
death. Do not proceed beyond a warning until all conditions have been met.
Caution. A caution is used to indicate a condition which, if not met, could cause minor or moderate personal injury and / or
damage to the equipment. Do not proceed beyond a caution until all conditions have been met.
Note. A note is used to indicate important information or instructions that should be considered before operating the equipment.
1.5 Symbols
1.5.1 Navigator 550 sodium wet-section
Symbols that appear on this product are shown below:
Direct current supply only.
This symbol, when noted on a product, indicates a potential hazard which could cause serious personal injury and / or
death.
The user should reference this instruction manual for operation and / or safety information.
This symbol identifies a risk of chemical harm and indicates that only individuals qualified and trained to work with
chemicals should handle chemicals or perform maintenance on chemical delivery systems associated with the
equipment.
This symbol indicates the need for protective eye wear.
This symbol indicates the need for protective hand wear.
Electrical equipment marked with this symbol may not be disposed of in European public disposal systems. In
conformity with European local and national regulations, European electrical equipment users must now return old or
end-of-life equipment to the manufacturer for disposal at no charge to the user.
Navigator 500
1.5.2 Navigator 540 transmitter

Symbols that appear on this product are shown below:
Functional earth (ground) terminal.
Protective earth.
Alternating current supply only.
This symbol, when noted on a product, indicates a potential hazard which could cause serious personal injury and / or
death.
The user should reference this instruction manual for operation and / or safety information.
This symbol, when noted on a product enclosure or barrier, indicates that a risk of electrical shock and / or electrocution
exists and indicates that only individuals qualified to work with hazardous voltages should open the enclosure or remove
the barrier.
Recycle separately from general waste under the WEEE directive
1.6 Product recycling and disposal (Europe only)

Electrical equipment marked with this symbol may not be disposed of in European public disposal systems after 12
August 2005. To conform to European local and national regulations (EU Directive 2002/96/EC), European electrical
equipment users must now return old or end-of-life equipment to the manufacturer for disposal at no charge to the user.
ABB is committed to ensuring that the risk of any environmental damage or pollution caused by any of its products is
minimized as far as possible.
Note. For return for recycling, please contact the equipment manufacturer or supplier for instructions on how to return end-of-life
equipment for proper disposal.
1.6.1 End-of-life battery disposal

The transmitter contains a small lithium battery (located on the processor / display board) that must be removed and disposed of
responsibly in accordance with local environmental regulations.
1.7 Restriction of Hazardous Substances (RoHS)

The European Union RoHS Directive and subsequent regulations introduced in member states and other countries limits
the use of six hazardous substances used in the manufacturing of electrical and electronic equipment. Currently,
monitoring and control monitors do not fall within the scope of the RoHS Directive, however ABB has taken the decision
to adopt the recommendations in the Directive as the target for all future product design and component purchasing.
Navigator 500
Sodium analyzer 2 Overview
2 Overview
2.1 Navigator 550 sodium wet-section
The Navigator 550 sodium wet-section has been designed for use with an ABB Navigator 540 transmitter to provide continuous
monitoring and control of power station boiler feed water / steam condensate. Sampling points include mixed bed outlets in water
treatment plants, extraction pump discharge, boiler feed, boiler drum and steam.
The wet-section contains a sodium ion responsive electrode and a silver / silver chloride reference electrode housed in an acrylic
flowcell. The electrode pair measures the sodium concentration in the sample. The flowcell houses a temperature sensor for
temperature compensation, sample stream valves and calibration valves.
The measurement range specification is 0.01 ppb to 10,000 ppb. The correct pH value of the sample is achieved by pre-treatment
with an alkaline vapor*. Calibration is achieved by exposing the sensor to calibration solution* with the low and high calibration valves.
A calibration can be initiated manually when required, or automatically with programmable daily frequency ranges, from 1 to 7 days
and 1 to 8 weeks.
*For information about reagent solutions, contact the local ABB representative.
Reagent tube bottle to entrainment T-piece Regeneration solution bottle (optional)
Reagent bottle
Calibration solution 1 bottle
Calibration solution 2 bottle
Bottle carrier
Quick-disconnect (QD)
couplings to solution bottles
Constant-head unit
Reagent tube to entrainment T-piece Navigator 500 Regeneration solution tubing (optional) to
Calibration + Regeneration valve
Remote reference reservoir (optional) Calibration solution 1tubing to

Calibration solution 2 tubing to
Calibration + Regeneration valve assembly
Entrainment 'T' piece

Sample outlet (drain) tubing
Calibration + Regeneration valve to stream
switching valve assembly Manifold valve assembly
(multi-stream wet-sections only)
Sodium electrode
Stream switching valve assembly
Reference electrode
Pt1000 temperature compensator
Stud terminal (ground) Sample stream inlets (front entry)
Sample stream drain tubing

Flowcell (rear drain outlet)
Fig. 2.1 Sodium wet-section main components (multi-stream version without flowmeters shown)
Navigator 500
Sodium analyzer 2 Overview
2.2 Navigator 540 transmitter

The Navigator 540 transmitter is designed for continuous monitoring and control of power station boiler feed water / steam
condensate and must be used in conjunction with an associated ABB wet-section to measure levels of low level dissolved oxygen /
sodium / hydrazine. Wet-sections are parameter-specific.
Information from the wet-section is sent to the transmitter via a communication board, where the process reading is displayed on the
main page and can be displayed as a graph in the Chart View – refer to Section 6.7, page 33 for details of view options.
Diagnostic messages inform the user of the analyzer status and can be logged for review. The analyzer status can also be assessed
remotely using programmable alarms, current output diagnostic functions, using optional Ethernet communications.
The transmitter has a multiple wet-section capability which enables it to control and display information from up to 4 wet-sections
(excludes multi-stream wet-sections). Section 3.3, page 13 shows an example of the multiple wet-section set up.
Mounting bracket
Display
Keypad
Transmitter door lock
Gland / cable entries
Fig. 2.2 Navigator 540 transmitter – main components
Navigator 500
Sodium analyzer 3 Installation
3 Installation
3.1 Installing the wet-section
3.1.1 Sample requirements 3.1.2 Location
Ensure the sampling point is as close as possible to the For general location requirements refer to Fig. 3.1. Install in a
wet-section and provides a thoroughly-mixed representative clean, dry, well ventilated and vibration-free location giving easy
sample. access. Avoid rooms containing corrosive gases or vapors, for
example, chlorination equipment or chlorine gas cylinders.
 Sample must contain less than 10 ppm suspended solids
with a particle size no greater than 60 µm. (If particle sizes Select a location away from strong electrical and magnetic
exceed 60 µm, use a 60 µm filter.) fields. If this is not possible, particularly in applications where
mobile communications equipment is expected to be used,
 Sample temperature must be within the range 5 to 55 °C
screened cables within flexible, earthed metal conduit must be
(41 to 131 °F).
used.
 Sample flow rates must be within the range 100 to 400
The standard solution and reagent containers are mounted at
ml/min (6.10 to 24.4 to cu in./min.).
the top of the wet-section panel. Standard solution containers
 Sample must not exceed 1.5 bar gauge (21.75 psi). are connected via quick-disconnect (QD) couplings. If the
transmitter has to be mounted directly above the wet-section,
allow at least 270 mm (11 in.) separation between the two units
for access to solution containers.
Maximum cable distance – transmitter to

wet-section 30 m (98 ft.)
Minimum distance between top of wet

section / bottom of transmitter:
270 mm (11 in.)
55 °C
(131 °F)
Max. Navigator 500
Navigator 500
0 °C
(32 °F)
Min.
Humidity
0 to 95 %
Avoid vibration IP54
Fig. 3.1 Wet-section location
Navigator 500
3.1.3 Mounting the wet-section

Refer to Fig. 3.2 for wet-section dimensions. The wet-section weighs 4.5 kg (10 lb) – excluding bottle carrier and solutions.
Note. Clearance – the enclosure doors can open 180°. If mounting in a confined area, allow sufficient clearance for
door opening.
Dimensions in mm (in.)
Ø 7 (0.27)
Navigator 500
(26.30)*
668
384.8
384.8 CTRS
(15.15) 480
480
(18.90)
2 Holes Ø 7
(0.27)
80.2 (3.15)
18
210 (8.27) 110.5
110.5 281 290218.7 (0.7)
(4.35) (11.06 in.) (11.41 in.)
185
37 (1.45) 185 (7.28)
*When installing, allow a further 60 mm (2.36 in.) min. to remove the bottle carrier assembly,
or 135 mm (5.31 in.) min. to remove the calibration solution bottle from the carrier.
Fig. 3.2 Sodium wet-section dimensions
Referring to Fig. 3.3:

1. Mark the wall using the dimensions shown.
2. Drill and plug 3 holes A and B in the wall suitable for
M6 or 1/4 in. fixings.
3. Screw in top fixing A, leaving a gap of 20 mm
(0.78 in.) between the fixing head and the wall.
4. Hang the wet-section onto fixing A, ensuring the
wet-section is retained firmly against the wall.
Note. It is not possible to adjust fixing A once the

wet-section is placed over it.
386
(15.19)
5. Secure the wet-section to the wall using 2 fixings B.
210 (8.27)
Fig. 3.3 Mounting the wet-section
Navigator 500
3.1.4 Connecting the external sample lines
Note.
 Sample inlet tubing to the base of the wet-section is customer-supplied.
 Sample inlet tubing must have sufficient wall thickness to withstand the highest sample pressure. Keep tubing lengths
short.
 Keep sample drains as short as possible and vertical to enable the sample to drain freely.
 Where particulate matter is present (for example, magnetite in boiler samples) it is recommended that a 60 micron sample
filter is fitted to the sample inlet line.
To make external sample inlet connections:

1. Fit a shut-off valve (not supplied) at each sample inlet.
2. Connect sample inlet tubing as follows:
a. For multi-stream wet-sections without flowmeters, connect 1/4 in. ID (or equivalent) plastic tubing (1 tube per stream) to
barbed connectors A.
b. For multi-stream wet-sections with flowmeters, connect 3/8 in. ID (or equivalent) plastic tubing (1 per stream) to spigot on
flowmeters B.
c. For single-stream wet-sections without flowmeter, connect 1/4 in. ID (or equivalent) plastic tubing to barbed connector C.
d. For single-stream wet-sections with flowmeter, connect 3/8 in. ID (or equivalent) plastic tubing to spigot on flowmeter D.
3. Ensure the wet-section internal sample stream drain tubing and sample outlet tube is routed through the drain outlets at the
base of the wet-section and through the funnel E – refer to Fig. 8.5, page 65 (multi-stream) or Fig. 8.7, page 67
(single-stream) for tubing location details at the base of the wet-section enclosure.
4. Connect the flowcell drain tubing (customer-supplied) to the barbed connector at the base of the wet-section F.
Navigator 500
Fig. 3.4 Connecting the external sample lines
Navigator 500
3.1.5 Connecting the reagent / calibration / regeneration tubing

The following tubing connections must be made on site, all other tubing connections are factory-made. All other internal wet-section
tubing connections are factory-made.
1. Connect the end of reagent tubing A to the connector B on the reagent bottle.
2. Connect the calibration solution 2 tubing QD coupling plug C to the mating connector D at the base of the calibration
solution 2 bottle.
3. If an optional regeneration bottle is fitted, connect the regeneration solution tubing QD coupling plug E to the mating
connector F at the base of base of the regeneration solution bottle.
4. Connect the calibration solution 1 tubing QD coupling plug G to the mating connector H at the base of the calibration
solution 1 bottle.
Nav
igat
or 500
Entrainment
T-piece
To constant-head unit
Calibration + Regeneration
valve assembly
To flowcell
Fig. 3.5 Reagent, calibration and (optional) regeneration tubing connections
Navigator 500
3.2 Installing the transmitter

3.2.1 Transmitter optional accessories 3.2.3 Panel mounting
Optional accessories comprise:
Cable gland kit
3.2.2 Transmitter location 35 92

For transmitter general location requirements refer to Fig. 3.6. (1.4) (3.6)
Install in a clean, dry, well ventilated and vibration-free location
providing easy access. Avoid rooms containing corrosive gases
or vapors, for example, chlorination equipment or chlorine gas
cylinders.
Warning. The transmitter is not fitted with a switch – an

isolation device such as a switch or circuit breaker
conforming to local safety standards must be fitted to the
final installation. It must be fitted in close proximity to the
transmitter, within easy reach of the operator and marked
clearly as the isolation device for the transmitter.
Mounting panel –
maximum thickness
6 (0.236)
Eye-level location
Cable gland kit

– optional
Panel clamp anchor screw

torque values: 0.5 to 0.6 Nm
(4.42 to 5.31 lbf/in.)
Ambient temperature
55 °C
(131 °F)
Max.
–10 °C
(14 °F) Panel-mount kit –
Min. optional
186 +1.1
–0
Humidity
(7.32 +0.04
–0 )
0 to 95 %
186 +1.1
–0
(7.32 +0.04
–0 )
Avoid vibration
 40 (1.57)**
 40 (1.57)
Panel cut-out dimensions*
Fig. 3.6 Transmitter location * To DIN43700

**150 mm (6 in.) if (optional) cable glands fitted
Fig. 3.7 Transmitter panel-mount option
Navigator 500
3.2.4 Pipe mounting 3.2.5 Wall mounting
Dimensions in mm (in.) Dimensions in mm (in.)
213 (8.38) 214 (8.42)

200 (7.87) fixing centers
Fixing centers
194 62
(7.64) (2.44)
66 Ø6.4
(2.40) (0.25)
Cable gland kit Cable gland kit

– optional – optional
98 (3.85)
66 (2.6)
Fig. 3.9 Transmitter wall-mount option
3.3 Multiple wet-section setup

Fig. 3.10 shows the multiple wet-section setup (4 wet-sections
maximum).
Note.
 Maximum length of cable from transmitter to
single-stream wet-section(s) = 30 m (92 ft.).
 Multi-stream wet-sections cannot be connected.
Transmitter
30 m (92 ft.)
Maximum length of cable –
transmitter to (last) single-stream
Pipe diameters: wet-section
max. 62 (2.44) / min. 45 (1.77) Pipe-mount kit
– optional
L1 L2 L3 L4
Vertical Horizontal
configuration configuration
Multiple wet-sections connected in series
L1 + L2 + L3 + L4 = <30 m (92 ft.)
Fig. 3.8 Transmitter pipe-mount options
Fig. 3.10 Multiple wet-section setup – maximum cable length
Navigator 500
3.4 Electrical connections – wet-section

3.4.1 Solution ground
A stud terminal is located on the left hand side of the flow cell, see Fig. 2.1, page 6. This stud is provided so that the solution can be
grounded to ensure there is not a build up of static charge. Static charge can build up when high purity liquids flow over
non-conductive surfaces and may result in a noisy signal output. It is recommended that a 16/0.2 mm wire (green/yellow outer
insulation) is connected from the flow cell stud terminal of each wet-section to the nearest suitable equipotential earth; for example
the earth stud on the transmitter.
3.4.2 Accessing the wet-section PCB
This section is applicable only for multiple wet-section systems.
Note.
 For single wet-section systems, the Modbus cable is connected to the wet-section at the factory – only transmitter
connections are required.
 If additional wet-sections are added they must be connected in series – refer to Appendix C, page 78.
 The following procedure is required only when connecting additional wet-sections to an existing analyzer.
Warning. Isolate power supplies to the transmitter and wet-section before attempting to access the wet-section PCB.

1. Open the wet-section door by releasing the 2 door locks A.
2. Remove the 4 screws B and associated plastic screw retaining washers C holding the wet-section PCB cover in place and
remove the cover.
3. Feed the supplied communications cable through the channel in the rear corner of the main case (as fitted cable), then through
the cable gland and make the connections shown in 3.12, page 15.
Note. When refitting the cover, ensure that the O-ring seal D in the PCB housing is located correctly in its groove.
Stud terminal (ground)
Fig. 3.11 Accessing the wet-section PCB
Navigator 500
3.4.3 Wet-section PCB connections

Cable Color Terminal ID Description
Note.
Calibration valve
 Refer to Section 3.5.2, page 18, for connection details Green 7 Cal valve 1 +ve
at the transmitter. Brown 8 Cal valve 1 –ve
 Serial cable connections at each additional Red 9 Cal valve 2 +ve
wet-section are made into the same terminals IDs as Black 10 Cal valve 2 –ve
the factory-fitted serial cable. Yellow 11 Regen valve +ve
 Refer to Appendix C, page 78, for multiple Orange 12 Regen valve –ve
wet-section setup and serial connection details. Reserved for pump (connection via separate PCB)
Red 14 +ve
Black 18 –ve
Flowmeter (if fitted)
Stream 1
Red 13 +ve
Brown 15 GND
Black 17 –ve
B R SCR
G W
Stream 2 (multi-stream only)
Orange 20 +ve
Yellow 22 GND
Green 24 –ve
Stream 3 (multi-stream only)
Blue 19 +ve
Violet 21 GND
Grey 23 –ve
Pressure switch
Red – R (24 V)
Black – B (0 V)
Red 25 N/A
Green – G (Data +ve) Black 26 N/A
White – W (Data –ve) Reference electrode
Screen – SCR Black 32 N/A
Sodium electrode
Screen 34 N/A
Fig. 3.12 Additional serial cable connections Core 36 N/A
to multiple wet-sections Pt1000 temperature sensor
Red 33 N/A
Cable Color Terminal ID Description Blue 35 N/A
Serial Table 3.1 Factory-made connections (Continued)
Red R 24 V
Black B 0V
Green G Data +ve
White W Data –ve
Screen SCR Screen
Stream switch valve – single-stream
Red 1 Valve 1 +ve
Black 2 Valve 1 –ve
Stream switch valve – multi-stream
Green 1 Valve 1 +ve
Brown 2 Valve 1 –ve
Red 3 Valve 2 +ve
Black 4 Valve 2 –ve
Yellow 5 Valve 3 +ve
Orange 6 Valve 3 –ve
Table 3.1 Factory-made connections
Navigator 500
3.5 Electrical connections – transmitter

Warning.
 If the transmitter is used in a manner not specified by the Company, the protection provided by the equipment may be
impaired.
 Remove all power from supply, relay, any powered control circuits and high common mode voltages before accessing or
making any connections. Use cable appropriate for the load currents: 3-core cable rated 3 A and 75 °C (167 °F) minimum,
and voltage: 100 / 240 V that conform to either IEC 60227 or IEC 60245, or to the National Electrical Code (NEC) for the US,
or the Canadian Electrical Code for Canada. The terminals accept cables AWG 26 to 16 (0.14 to 1.5 mm2).
 Ensure the correct fuses are fitted – Fig. 3.14, page 18 for fuse details.
 Replacement of the internal battery must be carried out by an approved technician only.
 The transmitter conforms to Installation Category II of IEC 61010.
 All connections to secondary circuits must have insulation to required local safety standards. After installation, there must be
no access to live parts, for example, terminals. Use screened cable for signal inputs and relay connections. Route signal
leads and power cables separately, preferably in an earthed (grounded) flexible metal conduit.
 All equipment connected to the transmitter's terminals must comply with local safety standards (IEC 60950, EN61010-1).
 The ethernet and bus interface connectors must only be connected to SELV circuits.
USA and Canada Only
 The supplied cable glands are provided for the connection of signal input and ethernet communication wiring ONLY.
 The supplied cable glands and use of cable / flexible cord for connection of the mains power source to the mains input and
relay contact output terminals is not permitted in the USA or Canada.
 For connection to mains (the mains input and relay contact outputs), use only suitably rated field wiring insulated copper
conductors rated min. 300 V, 16 AWG, 90C. Route wires through suitably rated flexible conduits and fittings.
Navigator 500
3.5.1 Accessing the transmitter connection board
Note. Electrical connections to the wet-section connection B

board are identified in the Section 3.4.3, page 15. Before
fitting cable glands, identify the connections required and
cable gland entries to be used.
A
1. Using a suitable screwdriver, release door retaining screw
A and open the transmitter door.
2. Release cover plate retaining screw B and remove cover
plate C.
3. Slide retaining clip D off blanking plug E and remove
the blanking plug.
4. Fit cable gland F and secure using nut G.
5. Remove gland cover H and route mains power supply
cable J through it.
6. Route the cable through cable gland F and into the
enclosure case.
Note. Cable glands are supplied with single- and

twin-holed bushes. Use the single-holed bush for the
mains power cable. C
K
7. Make connections to the power supply connection

terminals K.
8. Tighten gland cover H.
9. Refit cover plate C and secure it with retaining screw
B.
10. Close the transmitter door and secure with door retaining
screw A.
SK5
I/O MODULE 3
F E
J
H
Fig. 3.13 Accessing the transmitter board and making electrical

connections
Navigator 500
3.5.2 Transmitter connections
I/O module 1 SK1
COMMUNICATIONS
RS485 SMART SENSOR
INTERFACE MODULE ANALOGUE OUTPUT BOARD
CM40/0215 ISS.1 CM40/0235
(shown fitted)
MODULE
COM
COM
N/C
N/C
+
–
+
–
SK4 SK5
SK5
OUT 3 OUT 4 RELAY RELAY

5 6
Optional SK2
I/O module 3 option card
FUSE RATING
SCREEN
GREEN
BLACK
~100 – 240V
WHITE
RED
3.15A (T)
50/60 Hz
communications module I/O MODULE 2 I/O MODULE
I/O MODULE 3
(shown fitted)
DIO COM
DIO1
DIO2
DIO3
DIO4
DIO5
DIO6
COM
COM
COM
COM
+24V
N/C
N/C
N/C
N/C
+ – + –
N/C
N/C
N/C
N/C
INT
1 2 3 4 5 N L
COMMS OUT 1 OUT 2

RELAY 1 RELAY 2 RELAY 3 RELAY 4
(Ethernet)
3 and 4 (optional)
Analog outputs
SK1
COMMUNICATIONS
RS485 SMART SENSOR

CM40/0235
MODULE
CM40/0215 ISS.1
COM
COM
N/C
N/C
+
+
–
–
SK4 SK5
Relay connections
5 and 6 (optional)
5 6
SK2
FUSE RATING
~100 – 240V
SCREEN
GREEN
BLACK
WHITE
3.15A (T)
50/60 Hz
RED
I/O MODULE 3
DIO COM
COM
COM
COM
COM
DIO1
DIO2
DIO3
DIO4
DIO5
DIO6
+24V
N/O
N/O
N/O
N/O
+ – + –
N/C
N/C
N/C
N/C
1 2 3 4 5 N L
INT
COMMS OUT 1 OUT 2

Comms. connections Digital I/O Analog output Relay connections Mains supply 100 V to 240 V
(Ethernet) connections connections 1 and 2 1 to 4 (standard) AC ±10 % (90 V min. to 264 V
(standard) max.) 50 / 60 Hz
Wet-section terminal connections Fuse 3.15 A Type T 100 to 240 V, 50/60 Hz
Fig. 3.14 Connections overview
3.5.3 Digital I/O, relays and analog output connections
Relays (1 to 4) Relays (5 and 6) INT +24 V (100 mA Max.)
N/O COM
Load L N
DIO 1 – 6 Load
COM N/C L
N Load
N/C
Load L
Analog outputs (1 to 4) Digital input (24 volt) Digital input (voltage-free)

INT +24 V
+ DIO 1 – 6
DIO 1 to 6
750 
–
Max.
DIO COM
DIO COM
Chart recorder
Fig. 3.15 Digital I/O, relays and analog output connections
Navigator 500
Sodium analyzer 4 Setup
4 Setup
This section describes how to set the analyzer up for first-time 7. Remove the supplied O-ring J (temporarily secured to
use. the top of the right-hand chamber) and fit it over the
reference electrode body.
If multiple wet-sections are to be connected to a transmitter, an
additional setup procedure is required – see Appendix C, page 8. Carefully position the reference electrode centrally in the
78. right-hand chamber K so that the ceramic plug L is
between 5 and 10 mm (0.2 to 0.4 in.) from the bottom of
Caution. Do not attempt to setup the analyzer unless the the chamber.
wet-section and transmitter are fully installed and ready for 9. Ensure O-ring M is fitted at the top of reference
operation. electrode.
10. Connect black-sleeved reference electrode connector N
4.1 Setting-up the wet-section to the top of reference electrode and tighten.
4.1.1 Fitting the electrodes
Note. O-rings must be fitted correctly and the inside of the

electrode connectors must be dry and completely sealed
(moisture reduces the circuit impedance and affects the
wet-section performance).

1. Unpack sodium electrode A and carefully remove the
rubber teat – retain the teat for storage. Unscrew (but do
not remove) plastic sleeve B and slide sodium electrode
A fully into plastic sleeve B.
2. Carefully tighten plastic sleeve B (with sodium electrode

A in place) until electrode bulb C passes through 5 – 10 mm
O-ring D. (0.19 to 0.38 in.)
Position the sodium electrode so that, when the plastic

sleeve is tightened against O-ring D, the electrode bulb
is just above the bottom of the flowcell chamber E.
3. Ensure O-ring F is fitted at the top of the sodium
electrode.
4. Connect red-sleeved sodium connector G to the top of
the sodium electrode and tighten.
5. Unpack reference electrode H and remove the rubber
teat – retain the teat for storage.
6. For systems without an optional reservoir, unplug the
black rubber filling hole plug I (check the reference
electrode has sufficient solution – top up if necessary).
For systems with an optional reservoir fitted, proceed to
step10, then connect the reservoir tube to the reference
electrode arm as described in Section 4.1.2, page 20.
Fig. 4.1 Fitting the sodium and reference electrodes
Navigator 500
Sodium analyzer 4 Setup
4.1.2 Fitting and filling the reservoir (option) 4.1.3 Sensor panel
1. Fill the reagent solution container with appropriate
Note. The reservoir is supplied partially-assembled. solution.
Assemble only immediately before using the wet-section (to 2. Open the shut-off valve upstream of the wet-section panel
avoid the possibility of solution drying out if the wet-section and adjust it until sample is overflowing from the overflow
is stored for any length of time). pipe of the constant-head unit.
The maximum and minimum flow rates are 400 to 100
Referring to Fig. 4.2: ml/min (24.4 to 6.10 cu in./min).
1. Push reservoir A into clip B. 3. Ensure that sample is passing from the constant-head unit
2. Slide the lower end of the reservoir tube C onto to the flowcell and that the entrainment of reagent is
reference electrode filler tube D. operating; the entrainment should be regular, not
intermittent.
Note. Ensure the reservoir tube is not kinked and Allow at least one hour before carrying out a calibration.
does not contain air bubbles.
4. If the wet-section is a multiple wet-section configuration,
3. Remove filler cap E from the reservoir A. check / set the DIP switches on the wet-section PCB –
see Appendix C, page 78.
4. Fill the reservoir with 3.5 KCI solution and squeeze the
reservoir tube C repeatedly to expel any bubbles. 5. Start-up the transmitter as described in the Section 4.2.
5. Unscrew filler plug G 1 turn from the fully-closed position 6. Perform a two-point calibration:
to avoid creating a vacuum. – for single-stream wet-sections refer to Section 5.2,
6. Ensure O-ring F is in place and replace filler cap E. page 22
– for multi-stream wet-sections refer to Section 5.3,
page 23
7. The wet-section is now ready for use.
4.2 Transmitter start-up

Ensure all electrical connections have been made and switch
the power to the transmitter on. If the wet-section is being
commissioned for the first time, programming and calibration of
parameters is required – refer to Section 5.2, page 22
(single-stream) or Section 5.3, page 23 (multi-stream) to perform
a calibration for the first time.
The menu structure, general operation and menu descriptions,
including Calibration are detailed Section 7, page 42.
Fig. 4.2 Fitting and filling the reservoir
Navigator 500
Sodium analyzer 5 Calibration
5 Calibration
This section describes how to calibrate the analyzer once it is 5.1 Accessing the Configuration level menus
operational. Calibrations are initiated via the Cal prompt The configuration level menus are used to configure the
displayed on Operator pages, or via the Calibration Level and wet-section(s) and set parameter values – see Fig. 7.1, page 42
Advanced Level menus or as a Scheduled calibration. for an overview of menus.
To enter Configuration Level menus:
Note.
1. Press the key (below the icon).
 Calibration menus can be accessed from the
Advanced level only – refer to Section 5.1 to access Navigator 10 : 34: 52
2012–04–15
the Calibrate level. Tag 1

 If calibration standard solution values need to be
changed from their default values, the values must be
set from the Advanced / Calibrate / Calibration Setup 2.93 ppb
menu only – refer to Section 5.1 to access the 21.7 °C

Calibrate level. Na
CAL
Caution. The Operator menus are displayed:

 Do not calibrate the analyzer until the wet-section and
Navigator 10 : 34: 52
2012–04–15
transmitter are installed and ready for operation – refer
to Section 4, page 19. Operator Pages
4.28
 Allow at least 1 hour for the wet-section to stabilize Data Views
before running a calibration. Logs ppb
Alarm Acknowledge
Manual Hold
Autoscroll 21.7 °C
Media Card
Enter Configuration
2. Press the key to select the Enter Configuration menu

and press the key (below the icon).
The Access Level page is displayed:
Access Level
Read Only
Calibrate
Advanced
Service
Back Select
3. Use the key to scroll to the Advanced access level

and press the key (below the Select prompt) to enter
the top level Configuration menus.
Use the / keys to scroll between top level menus
and press the key (below the Select prompt on each
top level menu) to enter that level.
Note.
 Refer to Section 7, page 42, for menu
descriptions.
 Refer to Section 6.1, page 29, for details of menu
navigation and parameter selection / adjustment.
Navigator 500
5.2 Performing a calibration for the first time – single-stream wet-section

To perform a quick two-point calibration from an Operator page:
1. Press the key (below the Cal prompt). 4. Press the key (below the Yes prompt on the Start
Calibration page).
2012–04–15
The Calibration page is displayed with a bar graph to

Tag 1
indicate calibration progress:
2.93 ppb Sodium 1
PV 2.93 ppb
21.7 °C
Na
CAL
SS1 100 ppb
The Calibrate page is displayed: Please Wait

Abort OK
Menu
At the end of the calibration, and if the calibration is

Calibrate
successful, the Active Slope, Active Offset, Last Slope and
Last Offset values in the Signals View are updated – see
Section 6.6, page 33 for details of View modes.
Note. The Active Slope and Active Offset values are

Exit Select not updated if the calibration fails. The Calibration Log
is updated with the Active Slope and Active Offset
2. Press the key (below the Select prompt). values.
The Calibrate / Sodium 1 (2, 3, 4) page is displayed.

5. To exit the Calibration page, press the key (below the
Calibrate OK prompt). Calibration continues and calibration
progress can be monitored from the Calibration View –
Sodium 1 see Fig. 5.1, page 24.
The Calibrate / Sodium page is displayed.
Calibrate
Sodium 1
Back Select
Use the / keys to select the wet-section to be

calibrated.
3. Press the key (below the Select prompt on the Back Select
Calibrate / Sodium 1 [2, 3, 4] page).
The Sodium 1 (2, 3 or 4) / Start Calibration page 6. Press the key (below the Back prompt).
is displayed: The Calibrate page is displayed:
Sodium 1
Menu
Start Calibration Calibrate
Exit Yes
Exit Select
7. Press the key (below the Exit prompt) to return to the

Operator page.
Navigator 500
5.3 Performing a calibration for the first time – 4. Press the key (below the Yes prompt on the Sodium
multi-stream wet-section Three Stream / Start Calibration page).
To perform a quick calibration from an Operator page:
The Calibration page is displayed with a bar graph to
1. Press the key (below the Cal prompt). indicate calibration progress:
2012–04–15 Sodium Three Stream
PV 2.93
Tag 1 09:57 30/01
2.93 ppb ppb

Tag 2 09:57 30/01
2.75 ppb SS1 100 ppb

Tag 3 09:57 30/01
2.25 ppb Please Wait

CAL Abort OK
The Calibrate page is displayed: At the end of the calibration, and if the calibration is
successful, the Active Slope, Active Offset, Last Slope and
Menu
Last Offset values in the Signals View are updated – see
Section 6.6, page 33 for details of View modes.
Calibrate
Note. The Active Slope and Active Offset values are
not updated if the calibration fails. The Calibration Log
is updated with the Active Slope and Active Offset
values.
Exit Select
5. To exit the Calibration page, press the key (below the

2. Press the key (below the Select prompt). OK prompt). Calibration continues and calibration
The Calibrate / Sodium Three Stream page is displayed. progress can be monitored from the Calibration View –
see Fig. 5.1, page 24.
Calibrate
The Calibrate / Sodium Three Stream page is displayed.
Sodium Three Stream Calibrate
Sodium Three Stream
Back Select
3. Press the key (below the Select prompt on the Back Select
Calibrate / Sodium Three Stream page).
The Sodium Three Stream / Start Calibration page is 6. Press the key (below the Back prompt on the
displayed: Calibrate / Sodium Three Stream page).
The Calibrate page is displayed:
Sodium Three Stream
Menu
Start Calibration
Calibrate
Exit Yes
Exit Select

Operator page.
Navigator 500
5.4 Calibration parameters – offset and slope 5.5.2 Monitoring calibration progress
A mV offset is calculated after a single-point or a two-point If the Calibration page is exited by press the key (below the
calibration. This value represents the difference in millivolt output OK prompt) before the calibration has completed, progress can
of the electrode pair compared to the ideal output. The slope is be monitored from the View mode – see Fig. 5.1.
calculated when a two-point calibration is performed and is an
indication of the quality of the electrode pair. A two-point 2012–08–16
Navigator 10:52:35
calibration can fail if the slope value is outside the pass criteria
S1
set in the software – refer to Table A.2, page 75, for a PV 2.93 ppb
description of the calibration pass limits.
SS1 100 ppb
5.5 Calibration options Low Calibration
Single-point or two-point calibrations can be performed
depending on the operating conditions. A single-point
calibration (low and high) adjusts the mV offset only, a two-point Calibrating CAL
calibration adjusts the mV offset and the slope (sensitivity) of the
electrode.
Fig. 5.1 Calibration view
Note. Perform a low-point calibration weekly and a At the end of the calibration, and if the calibration is successful,
two-point calibration monthly. However, a suitable schedule the Active Slope, Active Offset, Last Slope and Last Offset
must be set to suit the operating conditions and values in the Signals View are updated – see Section 6.6,
applications. page 33 for details of View modes.
5.5.1 Scheduled calibration Note. The Active Slope and Active Offset values are not
Automatic calibrations can be performed with a frequency of 1
updated if the calibration fails. The Calibration Log is
day to 8 weeks. Perform calibrations frequently to ensure
updated with the Active Slope and Active Offset values.
accurate readings and verify the performance of the
wet-section.
5.5.3 Abort calibration
To set up a scheduled calibration: Calibrations can be stopped manually by pressing the key
1. Access the configuration level Calibrate menu – (below the Abort prompt) while the Calibration page is displayed
see Section 5.1, page 21. (see page 22).
2. Configure the schedule at the Sensor 1 (4) (single-stream) The calibration valve closes enabling the sample to flow past the
or Sensor Three Stream / Scheduled Calibration / Type, sensor again. A calibration recovery period commences and the
Frequency, Interval and Time of Next Cal. menu options. Calibration Log displays Cal Aborted – see Section 6.7.1, page
35.
If the pressure switch on the constant-head unit detects there is
no solution present during the calibration, the calibration is
stopped automatically. The Diagnostic Log (see Section 6.7,
page 34) displays a Cal Failed diagnostic and No Low Cal or No
High Cal depending on the valve that was energized. The
Calibration Log displays a Cal Aborted entry – see Section
6.7.1, page 35.
Navigator 500
5.5.4 Process calibration procedure

The process calibration procedure can be used to make minor 3. Press the key to select the Enter Configuration menu
adjustments to the concentration value. When a process and press the key (below the icon).
calibration procedure has been run and has completed, a
Process Calibration (PC) offset is calculated. Subsequently, the
displayed concentration has this offset in concentration Access Level
subtracted from the measured sodium concentration.
The following steps describe how to take a sample from the Read Only
wet-section for independent tests and adjust the sodium Calibrate
concentration reading accordingly. If the sodium concentration Advanced
is already known, steps 1 and 10 can be omitted. Service
Note. Back Select
 Process calibrations should be used only to make

minor adjustments to the concentration value. If the 4. Use the key to scroll to the Advanced access level
displayed concentration differs significantly from the and press the key (below the Select prompt) to enter
expected concentration, perform a Two-Point the top level Configuration menus.
calibration from the Calibrate level – see Section 5. If the Calibrate page is not displayed, use the /
7.1.1, page 43. keys to scroll to the Calibrate page:
 A process calibration can be carried out only on
Menu
single-stream and multi-stream wet-sections with 1
stream enabled.
Calibrate
To run a Process Calibration procedure:

1. Obtain a clean sample vessel of suitable size for the
volume of sample required.
At the transmitter: Exit Select
2. Press the key (below the icon).

6. Press the key (below the Select prompt).
2012–04–15
– If one or more single-stream wet-sections are
Tag 1 connected, the Calibrate / Sodium 1 (2, 3, 4) page is
displayed:
2.93 ppb Calibrate
21.7 °C
Na Sodium 1
CAL
The Operator menus are displayed:
2012–04–15 Back Select
Operator Pages
– If a multi-stream wet-section is connected, the
4.28
Data Views
Logs ppb Calibrate / Sodium Three Stream page is displayed:
Alarm Acknowledge
Manual Hold
Autoscroll 21.7 °C Calibrate
Media Card
Enter Configuration Sodium Three Stream
Back Select
Navigator 500
7. Press the key (below the Select prompt). At the transmitter:

The Sensor 1 (4) / Sensor Three Stream page (dependent 11. Press the key (below the Yes prompt).
on single-stream / multi-stream configuration) is displayed
The Process Calibration / Sample Collection page is
with the Sensor Calibration menu selected:
displayed:
Sensor 1
Process Calibration
Sensor Calibration
Scheduled Calibration
Calibration Setup PV 2.93 ppb
Restore Defaults
Sample Collection
Back Select
Abort Start
8. Press the key (below the Select prompt on the Sensor

1 (4) / Sensor Three Stream page). Note. To abort the process calibration procedure
The Sensor Calibration page is displayed: during this collection press the key (below the
Abort prompt).
Sensor Calibration
12. Press the key (below the Start prompt).
Low Calibration
High Calibration The next Process Calibration / Sample Collection page is
Two-Point Cal displayed with a progress bar:
Regeneration Cycle
Process Calibration Process Calibration
Grab Sample
Back Select
AVG 2.92 ppb
Press the key to highlight the Process Calibration
menu.
9. Press the key (below the Select prompt). Sample Collection
Abort Stop
The Process Calibration page is displayed:
Process Calibration When sufficient sample has been collected in the sample
vessel, the collected sample must be analyzed using a
laboratory method or another analyzer to determine the
Start Procedure concentration of sodium in the sample.
13. Press the key (below the Stop prompt) to stop the
procedure manually.
No Yes Note. If the procedure is not stopped manually, it

stops automatically after 30 minutes.
At the wet-section:
10. Place the drain tube from the constant-head unit into the The next Process Calibration / Sample Complete page is
sample vessel (during the sampling period an average displayed with the progress bar populated:
sodium concentration value is determined).
Process Calibration
AVG 2.93 ppb
Sample Complete
Abort Continue
Navigator 500
14. Press the key (below the Continue prompt). When the calculation is finished, a new page showing the
new reading and process calibration offset values is
The next Process Calibration page displayed shows an
displayed
average of the reading obtained:
Process Calibration
Process Calibration
New 3.00 ppb

AVG 2.93 ppb
PC Offset 0.007
New 000.00
Exit
Next Continue
The Process Calibration (PC) Offset is displayed in the

A new value can be added at this page.
transmitter’s Signals View – see Section 6.6, page 33.
Note. If the new concentration value is not entered It is toggled with the Concentration Value. The Process
into the transmitter within 5 hours of the sample Calibration (PC) Offset is also displayed in the transmitter’s
collection the process calibration procedure is Calibration Log.
aborted automatically.
Note. The PC Offset can be removed from the
concentration calculation by carrying out a single- or
15. Use the / keys to move the cursor to the numeral
two-point calibration.
to be edited in the New 000.00 reading on the screen.
To enter the value, press the key (below the Next
prompt).
Sensor Calibration page
Process Calibration
Sensor Calibration
Process Calibration
AVG 2.93 ppb
New 00 3.00
Next Continue
Back Select
Once the new value has been entered, press the key
17. Press the key (below the Back prompt).
(below the Continue prompt).
The Calibrate page is displayed:
The process calibration offset is calculated and a page
with a moving time bard is displayed for the duration of the Menu
calculation:
Calibrate
Process Calibration
AVG 2.93 ppb

Exit Select
Abort 18. Press the key (below the Exit prompt) to exit the
configuration level menu.
Navigator 500
5.5.5 Grab sample 5.7 Regeneration procedure

Pour the sample to be measured into the High Calibration bottle If the sodium electrode is exposed to low concentrations (less
(it is advisable to rinse the bottle with the sample to remove the than 1 ppb) for prolonged periods of time, sodium ions are
residuals of the calibration solution). The grab sample procedure leached from the surface of the electrode into the sample. This
can then be initiated manually via the Calibration menu. The can accelerate the aging process of the electrode, resulting in
default grab sample time is 15 minutes but can be set between poor response times, inaccurate readings and a limitation to
10 and 60 minutes depending on the level of accuracy required respond to low sodium concentrations.
and the level of sodium to be measured.
It is recommended that the electrode is regenerated at regular
The grab sample is displayed on-screen as entry G and logged intervals to minimize this ageing process and ensure accurate,
in the Calibration Log – see Section 6.7, page 34. repeatable readings.
To set up a Grab Sample routine: Perform a regeneration procedure once a month either manually
1. Access the configuration level Calibrate menu – or automatically (if the Automatic Regeneration option is
see Section 5.1, page 21). available) prior to a two-point calibration:
 to perform an automatic regeneration, refer to Section 8.3,
2. Run the Grab Sample routine at the Sensor 1(4)
(single-stream) or Sensor Three Stream / Sensor page 61
Calibration / Grab Sample menu option.  to perform a manual regeneration, refer to Section 8.4,
page 63
5.6 Calibration timings
Low point and high point calibrations are 15 minutes each.
5.6.1 Recovery period
The recovery period allows time for the wet-section to return to
the Process Value after a calibration. Current outputs and
alarms are held during the recovery period if the Hold Output
option is enabled.
To enable the Hold Outputs option:
1. Access the configuration level Calibrate menu (see
Section 5.1, page 21).
2. Select Enable at the Sensor 1 (4) (single-stream) or Sensor
Three Stream / Hold Outputs menu option.
The default value for the recovery period is 15 minutes but can
be configured between 10 and 60 minutes.
Navigator 500
Sodium analyzer 6 Operation overview – transmitter
6 Operation overview – transmitter

6.1 Front panel keys
The transmitter is operated using the keys on the front panel. These enable local navigation and selection of software options on all
displays, acknowledgement and data logging and monitoring. Prompts associated with active keys are displayed on each screen.
Diagnostic messages are detailed in Appendix A.1, page 72, display icon descriptions are detailed in Section 6.10, page 40.
Fig. 6.1 Front panel keys
Key functions are described in the following table:
Key Function Description
Navigation key – left At menu level, selects the highlighted menu item, edit a selection or return to the previous
A and menu level.
Operator Level access key When Operator page is displayed, opens or closes the Operator menu.
Toggles the view between Operator pages, Diagnostic View and Calibration Log screens.
B View key
Note. Not enabled in Configuration mode.
C Up key Used to navigate up menu lists, highlight menu items and increase displayed values.
D Down key Used to navigate down menu lists, highlight menu items and decrease displayed values.
Toggles between:
 Operator pages (1 to 5) when an Operator page is selected at the Group key.
 View screens (Alarms, Outputs, Signals, Chart and Diagnostic) when the Diagnostic
E Group key View screen is selected at the Group key.
 Log screens (Alarm, Audit, Diagnostic and Calibration) when the Calibration Log
screen is selected at the Group key.
Note. Not enabled in Configuration mode.
Navigation key – right At menu level, selects the highlighted menu item, operation button or edits a selection.
F and
Cal shortcut key At Operator page level, used as a shortcut key to access the Calibrate level.
Table 6.1 Front panel key functions / descriptions
Navigator 500
6.2 Transmitter operation modes

The transmitter has 4 modes of operation – all modes are accessed from the Operator menu – see Fig. 6.2.
 Operating – used to display real-time wet-section values on Operating Pages – refer to Section 6.5, page 31.
 View – used to display diagnostic messages, alarms, output values, signals (including the flow rate where applicable) and (chart)
traces – refer to Section 6.6, page 33.
 Log – used to display recorded (diagnostic, calibration, audit) events and alarms – refer to Section 6.7, page 34.
 Configuration – used to configure the transmitter – refer to Section 7, page 42.
6.3 Operator menus
Note. Operator menus cannot be accessed directly from the Configuration level.
Referring to Fig. 6.2, Operator menus A are accessed from any Operating, View or Log page by pressing the key B.
To select Operator sub-menus (indicated by the arrow) press the key C.
Autoscroll
Manual hold
In
Enter Configuration Configuration CAL
A
B C
Fig. 6.2 Operator menus
Operator menus comprise:

 Operator Pages – displays the Operator Page for each available wet-section.
 Data Views – displays enabled data views.
 Logs – displays enabled Log views.
 Alarm Acknowledge – acknowledges the active alarm displayed in the Alarms View.
 Manual Hold – holds (freezes) the current outputs and alarms for the selected wet-section(s).
Note. Active values are still indicated on the display.
 Autoscroll (enabled on Operator pages only) – displays Operator pages sequentially when multiple wet-sections are fitted.
 Media Card – displays the status of the SD Card / USB stick (enabled only media module is fitted).
 Enter Configuration – enabled on all pages – enters Configuration parameters via the Access Level – refer to Section 6.9.2,
page 39 for access levels and password security options.
CAL shortcut – initiates a calibration directly from an Operator Page, press the key C (below the CAL prompt). This shortcut
opens the Calibrate page, bypassing the Configuration level menus.
Navigator 500
6.4 Navigation overview
Operator Operator Operator Operator Operator

Page 1 Page 2 Page 3 Page 4 Page 5
Diagnostics Signals Chart Alarms Outputs

View View View View View
Calibration Alarm Audit Diagnostic

Log Log Log Log
Fig. 6.3 Menu navigation
6.5 Operating mode

In operating mode, values from connected wet-sections are displayed on Operator Pages. A maximum of 5 Operator Pages can be
displayed.
Operator Page 1 (the default page) displays values from all connected wet-sections simultaneously (a maximum of 4 wet-sections
can be connected). The remaining Operator Pages can be assigned to display values from individual wet-sections (in any wet-section
order). To achieve this, each wet-section must be associated with a template in the Configuration level / Display / Operator Templates
parameters – see page 50.
In Fig. 6.4, Operator Page 1 shows that 4 wet-sections are connected.
Instrument tag
Navigator 2012–04–15
10 : 29: 17 Time and date
(user-assignable)
TAG 1 TAG 2
Wet-section tag 2.77 ppb 4.28 ppb
Process value (PV)
(user-assignable) Na
No UNa Na Parameter ID
TAG 3
Autoscroll icon –
scrolls each page
6.93 ppb 8.82 ppb Unit of measure
Na Na
sequentially when enabled
In Configuration CAL Display icon –
see Section 6.10, page 40
Display icon – Diagnostic message or alarm tag –
see Section 6.10, page 40 see Appendix A, page 72 for diagnostic messages
NAMUR (NE107) Status Icons
Failure High Process Alarm
Maintenance Low Process Alarm
Out of Spec High Latch Alarm
Check Function Low Latch Alarm
*The highest priority diagnostic or alarm is displayed. Other active diagnostic / alarm states can be viewed on the Diagnostics
View – see page 33.
Fig. 6.4 Operator Page 1 (sodium multiple wet-section)
Navigator 500
Fig. 6.5 shows an overview of Operator Pages 2 to 5. Each Operator Page displays the process value (PV) and temperature from a
single wet-section. Fixed, color-coded, user-assignable tags (one for each connected wet-section) and color-coded bargraphs aid
identification of each wet-section.
The bargraph indicates the PV (minimum and maximum values on the chart are configurable in the Sensor Setup level). If the PV is
above the maximum specified range of the wet-section, the bargraph flashes to indicate the value is out of range.
When multiple wet-sections are connected, and if Autoscroll is selected from the Operator Menu (see Fig. 6.2, page 30), the display
scrolls through each available Operator Page consecutively.
Color-coded
wet-section tag
wet-section 1 = red
Process value (PV)
wet-section 2 = green
wet-section 3 = blue Unit of measure
wet-section 4 = violet
Product tag Time / date
Navigator 2012–04–15
10 : 34: 52
(user-set)
Tag 1
Color-coded wet
4.28
section bargraph
Parameter ID
LLDO
ppb wet-section 1 = red
wet-section 2 = green
Sodium
Hydrazine 21.7 °C
wet-section 3 = blue
wet-section 4 = violet
Sodium
Temperature /
Operator Menu In Configuration CAL temperature unit
icon
Autoscroll
icon Diagnostic icon / Cal shortcut prompt
diagnostic message
Fig. 6.5 Operator Pages 2 to 5 – overview
Navigator 500
6.6 View mode

Pages displayed in View mode comprise:
 Diagnostics View – displays a list of diagnostic messages identified by priority and message – see Fig. 6.6
 Alarms View – displays a list a list of alarms identified by priority (sequence number), source and status – see Fig. 6.7
 Outputs View – displays a list of alarms identified by analog output ID, output value and percentage of output value
– see Fig. 6.8
 Signals View – displays a list of active signals and their values – see Fig. 6.9
 Chart View – represents the wet-section readings as a series of color-coded traces – see Fig. 6.10
NAMUR icon and message priority –

see page 72 Diagnostic message View icon
Diagnostics View 2012–04–15

10 : 31: 27
No. Message
01 Temp Failure S3
O2 NV Error S3
O3 Calibrating S3
O4 Recovery S3
CAL
Fig. 6.6 Diagnostics View
Setpoint Alarm source Alarm status
2012–04–25
Alarms View 10 : 31: 27
ID Setpoint Source Status Ack

Alarm ID A1 100.0 ppb  Alarm acknowledge
A2 100.0 ppb status (Y / N)
A3 100.0 ppb 
A4 100.0 ppb 
A5 – – – –
A6 – – – –
A7 – – – –
A8 – – – –
CAL
Fig. 6.7 Alarms View
Output value % of output value
2012–04–15
Outputs View 10 : 31: 27
Analog ID Output Percent

AO1 4.00 mA 0.0 %
output ID
AO2 4.00 mA 0.0 %
AO3 4.00 mA 0.0 %
AO4 4.00 mA 0.0 %
CAL
Fig. 6.8 Outputs View
Navigator 500
Signal value / efficiency indicator Units
Signals View 2012–04–15

10 : 31: 27
Sensor 1 Value Units

Signal type Concentration 8.25 ppb
Temperature 0.5 °C
Sensor Output 0.0 mA
Flow Rate 120 ml/min.
Efficiency
Last Efficiency
CAL
Scroll for additional signals
Fig. 6.9 Signals View
Color-coded trace
(1 for each wet-section) Process value
2012–04–15
Chart View 10 : 31: 27
Wet-section ID
(color-coded)
Trace
time / date
CAL
Fig. 6.10 Chart View
6.7 Log mode

Log mode pages display logged information in the sequence it occurred.
Log mode pages comprise:
 Calibration Log: a history of calibration routines.
 Alarm Log: a history of alarm events.
 Audit Log: a history of analyzer activity.
 Diagnostic Log: a history of diagnostic events.
Event description Event date
2012–04–25
Audit Log 10 : 31: 27
Log icon
No. Event Date Time
01 Power Failure 07:04:13 14:03:24
02 Power Recovery 07:04:13 14:17:03
03 Power Failure 08:04:13 14:21:54
04 Power Recovery 08:04:13 14:26:31
Alarm number / icon* Event time

CAL
in occurrence order
*Icons not displayed on Alarm Log or Calibration Log
Fig. 6.11 Log page (example of Audit Log shown)
Navigator 500
6.7.1 Calibration log entries

Possible calibration log entries along with a description are shown in Table 6.2. The possible Audit Log entries along with a
description are shown in Table 6.3. The Diagnostic Log shows the history of diagnostic messages that have been displayed in the
Diagnostic View – see Appendix A, page 72 for diagnostic messages.
Log entry Description
Cal Failed Calibration procedure failed due to high / low slope or out of calibration solution or sample
temperature error during a calibration procedure.
Cal Aborted Calibration aborted manually by the user.
Cal Missed Scheduled calibration missed due to:

– user being in Man. Valve Control menu.
– manual calibration in progress (on same wet-section)
– user in Service login.
This log entry is also displayed if a calibration associated with a regeneration is missed due
to No Sample state.
Coefficients The Slope and mV Offset are displayed – refer to Section 5.4, page 24 for a description of
(Slope and mV Offset) these coefficients.
Table 6.2 Calibration Log entries
Log entry Description
Power Failure Power to the transmitter is lost.
Power Recovery Transmitter restarted after a power loss.
In Config. User in Advanced / Configuration mode.
Time / Date Changed User has changed date / time.
Daylight Saving Time changed due to daylight saving.
Table 6.3 Audit Log entries
Navigator 500
6.8 Logging 6.8.1 SD card / USB stick

Data recorded in the transmitter's internal memory can be
archived to a removable Secure Digital (SD) card or USB stick. Caution. To avoid potential damage or corruption to data
The transmitter continuously records all data to its internal recorded on an SD card / USB stick, take care when
memory and keeps track of which data has been archived. handling and storing. Do not expose to static electricity,
electrical noise or magnetic fields. When handling the SD
card / USB stick take care not to touch any exposed metal
Note. ABB's DataManager software can be used to store
contacts.
and view data archived from the transmitter.
There are two methods of archiving to an SD card / USB stick:

The amount of time that data remains in the transmitter's
internal memory depends on the sample rate – see Table 6.4.  An SD card / USB stick is kept in the transmitter
Sample data is saved to removable media as comma-separated Data is archived to the SD card / USB stick automatically
files. at set intervals. Archiving continues until the SD card /
Configuration files are saved as binary-encoded files. Additional USB stick full; archiving then stops. To ensure all required
files can also be archived: data is archived successfully, the SD card / USB stick
should be swapped periodically for an empty one.
 Event log files (these files contain Audit Log, Alarm Log,
Diagnostic Log and Calibration Log data)
Note. It is not advisable to leave a USB stick in the
 Data log files transmitter permanently.
 Configuration files
The transmitter’s internal memory supports a maximum of 10 It is advisable to back-up critical data stored on an SD
Data Log and Event Log files only and a maximum of 8 card / USB stick regularly. The transmitter's internal
Configuration files. Durations for continuous recording are memory provides a buffer for the most recent data only
shown in Table 6.4 (internal storage). so, if data stored on an SD / USB stick card is lost, it can
be re-archived.
5s 10 s 30 s 1m 5 / 10 / 30 m 1 hr  Data is copied to an SD card / USB stick when
30 60 180 300 300 300 required
days days days days days days When a SD card / USB stick is inserted into the
Table 6.4 Internal (flash) memory storage capacity transmitter, the media status can be set to Online causing
unarchived data to be copied to the media – see Section
7, page 42 / Media Card menu level.
A 2GB SD card / USB stick has sufficient external storage
capacity for >5 years data.
Navigator 500
6.8.2 SD card / USB stick insertion and removal 6.8.3 Archive file types
To access the SD card / USB stick: All archive files created by the transmitter (except for
configuration files) are assigned filenames automatically. Each
1. Ensure the transmitter is offline.
type of archived file is assigned a different file extension.
2. Use a large Pozi-drive screwdriver to release the door
Archive files are created as text format data files.
catch A.
The file type and extension for Data text files is '.DOO'
3. Open the door and insert the SD card / USB stick B.
 <ddmmyy><hhmmss><monitor tag>.DOO
The red LED C is lit when the SD card / USB stick is in
use by the transmitter.
The file type and extension for Event log files (containing
4. To remove the SD card / USB stick, if the red LED is lit, historical entries from the Audit, Calibration, Diagnostic and
press button D and wait until the LED goes out. Alarm logs is '.AOO’.
5. Pull the SD card / USB stick out of its socket. The SD card  <ddmmyy><hhmmss><monitor tag>.AOO
/ USB stick can then be inserted into an appropriate card
reader USB port on the PC and the data downloaded.
Note.
 The 'monitor tag' is set in the Device Setup level (see
page 42) when the user has access at Advanced level
– see Section 6.9, page 39.
 The time and date are formatted according to the
format set in Display / Date & Time level – see
page 42.
The transmitter's internal clock can be configured to
adjust automatically at the start and end of Daylight
Saving periods – see page 42.
Configuration filenames are user-entered. The configuration file

type and extension is '.cfg’.
6.8.4 Data files
Text format archived data is stored in a comma-separated value
Fig. 6.12 SD card / USB stick insertion and removal
(CSV) format and can be imported directly into a standard
spreadsheet, for example, Microsoft® Excel.
Note. Data stored in the internal memory buffer can still be Alternatively, you can carry out detailed graphical analysis of the
transferred to the SD card / USB stick when the archive data on a PC using ABB’s DataManager data analysis software.
media is placed on-line again (providing it is not off-line so New data files are created in the following circumstances:
long that the un-archived data in the internal memory is
overwritten).  The transmitter configuration is changed.
 One of the current files exceeds the maximum permissible
size (a new file is created at 12:00 a.m. on the following
day. Data is logged into the existing file continuously until
the new file is created.
 When the daylight saving period starts or ends.
 When working files cannot be found / are corrupted.
The filename is formatted as follows:
 Data logs: <ddmmyy><hhmmss><monitor tag>.DOO
Navigator 500
6.8.5 Log files

The Alarm Event, Calibration, Diagnostic and Audit logs are
archived into the same file. The filenames are formatted as
follows:
 Event logs: <ddmmyy><hhmmss><instrument tag>.AOO
6.8.6 Daylight saving
Files containing data generated during the daylight saving period
have '~DS' appended to the filename.
Start of daylight saving period
A daily file is started at 00:00:00 on 30th March 2013 filename:
30Mar13ASO550.D00
Summertime starts at 2:00am on 30th March 2013 and the clock

changes automatically to 3:00am.
The existing file is closed and a new file is created filename:
30Mar13ASO550~DS.D00
The file '30Mar13ASO550.D00' contains data generated from

00:00:00 to 01:59:59.
The file '30Mar13ASO550~DS.D00' contains data generated
from 03:00:00.
End of daylight saving period
A daily file is started at 00:00:00 on 26th October 2013 filename:
26Oct13ASO550~DS.D00
Summertime ends at 3:00am on 26th October 2013 and the

clock changes automatically to 2:00am.
The existing file is closed and a new file is created filename:
26Oct13ASO550.D00
The file '26Oct13ASO550~DS.D00' contains data generated
from 00:00:00 to 02:59:59.
The file '26Oct13ASO550.D00' contains data generated from
02:00:00.
Note. Daily files start at 00:00:00.
Navigator 500
6.9 Password security and Access Level

Passwords are entered at the Enter Password screen accessed via the Access Level – see Section 6.9.2, below.
6.9.1 Setting passwords
Passwords can be set to enable secure access at 2 levels: Calibrate and Advanced. The Service level is password protected at the
factory and reserved for factory use only.
Passwords can contain up to 6 characters and are set, changed or restored to their default settings at the Device Setup / Security
Setup parameter – see page 48.
Note. When the transmitter is powered-up for the first time, the Calibrate and Advanced levels are not password protected.
Protected access to these levels can be allocated as required.
6.9.2 Access Level

The Access Level is entered via the Operator menu / Enter Configuration menu option – see Section 6.3, page 30.
Access Level
Logout
Access levels – Read Only
scroll to level and press
Calibrate
Select key to enter
Advanced
Service
Back key Back Select

Select key –
used to enter levels or
Enter Password screen
Fig. 6.13 Access Level
Level Access
Logout Displayed after Calibrate or Advanced level are accessed. Logs the user out of current level. If
passwords are set, a password must be entered to access these levels again after selecting Logout.
Read Only View all parameters in read-only mode.
Calibrate Enables access and adjustment of Calibrate parameters (refer to Section 5, page 21 for calibration
details).
Advanced Enables configuration access to all parameters.
Service level Reserved for authorized service technicians only.
Enter Password
Cursor / Password
character indicator Cursor – scroll characters using the
(maximum 6 characters) / keys;
press to accept character; press
to accept password while last
character is highlighted
Fig. 6.14 Enter Password screen
Navigator 500
6.10 Display icons

6.10.1 Diagnostic icons 6.10.2 Title bar icons
Note. Log mode – indicates that one of the View pages

is currently displayed (Calibration, Alarm, Audit or
 When a diagnostic condition is detected the Diagnostic)
associated NAMUR icon plus the highest priority
diagnostic message is displayed in the Status Bar View mode – indicates that one of the View
when the transmitter is in Operator View mode – refer pages is currently displayed (Diagnostics,
to Appendix A, page 72 for diagnostic messages. Alarms, Outputs, Signals or Chart).
 If the status bar displays a diagnostic message, press
the key to see all diagnostic messages. Media on-line: 0 to <20 % full.
NAMUR icons Media on-line: 20 to <40 % full.
Diagnostic icon – Out of Specification. Media on-line: 40 to <60 % full.
Diagnostic icon – Maintenance Required. Media on-line: 60 to <80 % full.
Media on-line: 80 to <100 % full.

Diagnostic icon – Failure.
Media on-line: full (icon toggles when full).

Diagnostic icon – Check Function.
Media off-line: 0 to <20 % full.
Alarm, Hold and Calibration icons

Alarm – indicates a user-defined alarm condition
(20-character) and flashes intermittently with an
associated NAMUR diagnostic icon. Media off-line: 40 to <60 % full.
Hold – indicates that alarms / analog outputs are
in a manual hold state. Media off-line: 60 to <80 % full.
Calibrating – indicates that a calibration is in

progress.
Media off-line: not inserted (not logging).
Media off-line: not inserted, logging active

– icon display toggles with Media off-line: not
inserted (not logging) icon.
Navigator 500
6.10.3 Log icons 6.10.4 Status bar icons
T1 Source: wet-section 1 (red) Operator menu – displays the Operator menu

S1 = sensor for wet-section 1 when the key is pressed.
T1 = temperature for wet-section 1
Autoscroll – selected from the Operator menu
Source wet-section 2 (green) (displayed when Autoscroll enabled). Indicates
T2 Operator pages are displayed sequentially.
S2 = sensor for wet-section 2
T2 = temperature for wet-section 2 Disabled if 1 Operator page only is configured for
display.
Source wet-section 3 (blue)
T3 Calibration – shortcut access to the Calibration
page when the key is pressed.
T3 = temperature for wet-section 3
Enter – selects the highlighted option from the
T1 Source wet-section 4 (violet) Operator menus when the key is pressed.
T4 = temperature for wet-section 4 Service Level – indicates that alarms and analog
outputs are held.
Power failed / power failed
Advanced Level – indicates that Advanced Level
parameters are enabled for the current user.
Configuration changed
Calibrate Level – indicates that the Calibration
Level parameters are enabled for the current
user.
System Error
Read Only Level – indicates that the transmitter
is in Read Only mode. All parameters are locked
File created / deleted and in cannot be configured.
Media inserted / removed
Media on-line / off-line
Media full
Date / time or daylight saving start / end

changed
High process alarm active / inactive
Low process alarm – active / inactive
High latch alarm – active / inactive
Low latch alarm – active / inactive
Alarm acknowledged
Navigator 500
Sodium analyzer 7 Menu descriptions
7 Menu descriptions
7.1 Menu overview
Refer to Section 7.1.1, page 43 Refer to Section 7.1.2, page 46 Refer to Section 7.1.3, page 48
Menu Menu Menu
Calibrate Sensor Setup Device Setup
Exit Select Exit Select Exit Select
Sodium 1 – 4 Sodium 1 – 4 Initial Setup

Sensor Calibration Calibration Setup Tag Stream Settings Instrument Tag
Low Calibration Low Std Solution Stream 1 (3) Tag Sample Time Temperature Units
High Calibration High Std Solution Units Sequence Reset to Defaults
Two-Point Cal Recovery Time Range High Stream 1 (3)
Regeneration Cycle Grab Sample Time Stream 1 (3) Range High Man. Valve Control Security Setup
Process Calibration Restore Defaults Range Low Calibrate Password
Grab Sample Low Standard Valve
Stream 1 (3) Range Low Advanced Password
Scheduled Calibration Hold Outputs High Standard Valve
Filter Type Reset Passwords
Type Stream Valve
Filter Time
Frequency Stream Valve 1 (3) Range Change Setup
Wetting Routine
Interval Regeneration Valve
Solution Detection Range Change
Time of Next Cal.
Flow Meter Reset to Defaults Range 1(3) Span
Flow Meter 1 – 3
Menu Menu Menu
Display Input/Output Process Alarm
Language Settings Analog Outputs Digital I/O Alarm 1 – 8

Operator Templates Brightness Analog Output 1 – 4 Digital I/O 1 – 6 Source
Page 1 (5) Template Contrast Source Type Type
Date & Time Output Type Source Tag
Chart View Polarity Trip
Channel 1 – 4 Date Format Elec. Low
Time & Date Elec. High Relays Hysteresis
Source Time Hysteresis
Tag Daylight Saving Eng. Low Relay 1 – 6
Chart Duration Eng. High
DS Region Output Failure Source
View/Log Enables DS Start Time Failure Current Polarity
Diagnostic View DS End Time
Signals View DS Start Occur
Chart View DS End Occur
Alarm View DS Start Day
Analog OP View DS End Day
Calibration Log DS Start Month
Alarm Log DS End Month
Audit Log
Menu Menu Menu
Media Card Communication Device Info
Profibus Transmitter Media Card Unit

Card Status
Slave Address Serial Number Software Version
Process Data Baud rate Hardware Version
Date of manufacture
Channel 1 – 6 Ethernet Hardware Revision
Sampling Time Software Revision Sensor 1 – 4
DHCP
IP Address Type
Data Logging Ethernet Serial Number
Subnet Mask
Save Configuration Default Gateway Ethernet Revision Date of manufacture
MAC Address Hardware Revision
Select File Name (8) Email Software Revision
Load Configuration SMTP Server ID Input/Output
Select File (8) Recipients No. Analog Inputs
Email Address 1 – 3 No. Analog Outputs
Quick Format Triggers No. Relays
Tag 1 – 4
Source 1 – 4
Note. Service level menus (not shown) are Invert 1 – 4
password-protected at the factory and intended for
use by authorised ABB service technicians only.
Fig. 7.1 Overview of sodium menus
Navigator 500
7.1.1 Calibrate
Menu Used to calibrate the wet-section, regenerate the wet-section, set up calibration parameters,
process calibrations and initiate Grab Sample routines.
Calibrate
Access to the Calibrate menu is permitted via the Calibrate and Advanced levels only.
Exit Select
Menu Comment Defaults
Sodium 1 – 4 The identity of the sodium wet-section being calibrated

(if a sodium multi-steam wet-section, Sodium only is displayed).
Sensor Calibration
Low Calibration Performs a single-point offset calibration using the low standard 15 min.
calibration solution. The default calibration time is 15 minutes and is
followed by a Recovery period.
The active offset value is adjusted after this calibration. This calibration
adjusts for any drift in the reading and should be performed weekly or
as required.
Note: During the calibration the sample is directed to drain via the
sample stream valve.
High Calibration Performs a single-point span calibration using the high standard 15 min.
calibration solution. The default calibration time is 15 minutes and is
followed by a Recovery period.
The active offset value is adjusted after this calibration.
Two-Point Cal Performs a two-point calibration. 30 min.
Runs both a low calibration and a high calibration. The total default
calibration time is 30 minutes and is followed by a Recovery period.
The active offset value and slope are calculated after this calibration.
This calibration compensates for any drift in the reading and changes
in the sensitivity and should be performed weekly or as required.
If the slope is calculated to be less than 80 % or greater than 110 %
the calibration has failed, a Cal Failed diagnostic appears and the offset
and slope are not updated.
Regeneration Cycle Displayed only if Regeneration Fitted is enabled.
Performs a regeneration automatically followed by a two-point
calibration. The regeneration procedure energizes the regeneration
valve (if fitted) for 1 minute to expose the electrode to the regeneration
solution.
A regeneration recovery period is then initiated, which last for 2 hours.
The recovery period is followed by a two-point calibration.
Refer to Section 5.7, page 28 for more details of the Regeneration
procedure.
Continued on next page…
Navigator 500
Process Calibration Performs a process calibration. This calibration can be used to adjust
the concentration value on the wet-section to a value that has been
determined in the laboratory. It should only be used to make minor
adjustments to the reading.
A large discrepancy between the lab and wet-section readings could
be due to errors in calibration solutions or indicate problems with the
wet-section.
A Process Calibration can not be initiated on a multi-stream transmitter
unless one stream only is enabled.
Note: There is no recovery period after a process calibration.
Grab Sample Performs a Grab Sample routine. The Grab Sample function can be
used to measure the sodium concentration of an external sample, for
example, from another point in the process.
Note: During a grab sample routine the sample connected to the
wet-section is directed to drain via the sample stream valve.
Type Selects the type of scheduled calibration.
Off
Low Standard Cal.
High Standard Cal.
Two-Point Cal.
Regeneration Cycle
Frequency Selects the scheduled calibration frequency.
Off
Selectable options: Daily, 2, 3, 4, 5, 6, 7 days.
Daily
Selectable options: Weekly, 2, 3, 4, 5, 6, 7, 8 weeks.
Weekly
Interval Selects the scheduled calibration interval.
Time of Next Cal. Selects the time and date of the next and subsequent scheduled 2000.01.01
calibrations. 00:00:00
Scheduled calibrations are not performed until the date / time set is
reached. The date of the next scheduled calibration is updated
automatically according to the frequency set. For example, if
Frequency is 5 days and Time of Next Cal. is12:00:00 2013-01-05, it
is updated automatically to: 12:00:00 2013-01-10.
Note: If the scheduled calibration cannot be run, or is not successful,
the next scheduled calibration date is updated according to the
Frequency set and a Missed Scheduled Cal. diagnostic message is
created. Parameters are not enabled if Frequency is Off.
Navigator 500
Calibration Setup
Low Std Solution Sets the low standard calibration solution value between 50 and 100 ppb
10,000 ppb.
High Std Solution Sets the high standard calibration solution value between 50 and 1000 ppb
10,000 ppb.
Recovery Time Sets the recovery time in minutes (between 10 and 60 minutes). 15 min.
This value can be adjusted to ensure the wet-section has adequate
time to reach a stable reading after a calibration.
The default setting is 15 minutes, but this may need to be extended if
the process concentration is very low; especially if a high calibration
has been carried out.
Grab Sample Time Sets the grab sampling time in minutes. 15 min.
Restore Defaults Restores Calibrate parameters to their default values / settings.
Hold Outputs Enables / Disables the Hold Outputs function.

Outputs include current outputs and alarms.
Navigator 500
7.1.2 Sensor Setup
Menu Used to set the wet-section tag, measurement units, operational and stream ranges and filter type
and enable / disable the Flow Meter (optional) and Manual Valve Control functions.
Sensor Setup
Exit Select
Menu Comment Default
Sodium 1 – 4 The identity of the sodium wet-section being set up (if a sodium
multi-steam wet-section, Sodium only is displayed).
Tag Note: Single-stream wet-sections only. TAG 1

Sets the (colored) 16-character alphanumeric wet-section tag
displayed on Operator Pages.
Stream 1 (3) Tag Note: Multi-stream wet-sections only.

Sets the 16-character alphanumeric tag for each selected stream
displayed on Operator Pages.
Units Selects the measurement units:

ppb / µg/l / µg/kg. ppb
Range High Note. Single-stream wet-sections only.

Sets the range span in Chart and Bargraph views.
Stream 1 (3) Note. Multi-stream wet-sections only.

Range High
Sets the range span in Chart and Bargraph views.
Range Low Note. Single-stream wet-sections.

Sets the range zero in Chart and Bargraph views.
Stream 1 (3) Note. Multi-stream wet-sections only.

Range Low
Sets the range zero in Chart and Bargraph views.
Filter Type Selects the filter type:

Off / Min / Max / Average / Rolling Point. Off
Filter Time Sets the filter (input) time (5 to 100 seconds). 5 seconds
Wetting Routine Enables / disables the wetting routine. The wetting routine is initiated
when a No Samples situation is detected. It energizes the high
calibration solution valve for 1 minute every 24 hours.
The wetting routine is terminated if sample returns.
Navigator 500
Solution Detection Enables / disables the solution detection function.
Flow Meter Note. Single-stream wet-sections only.

Enables / disables flow measurement. Disabled
Flow Meter 1 – 3 Note. Multi-stream wet-sections only.

Enables / disables flow measurement for the selected stream. Disabled
Stream Settings Note. Multi-stream wet-sections only.
Sample Time Sets the how long each stream is sampled. 15 min.
Sequence Sets the order in which the streams are sampled, a maximum of 8 1,2,3,1,2,3,1,2,1
entries are permitted. A 0 indicates the end of the sequence. (3-stream)
An example sequence for streams 1 to 3 is: 1,2,3,1,2,3,0 where the 3
streams are sampled consecutively.
Stream 1 (3) Enables / Disables the selected stream (disabled streams are not sampled).
Man. Valve Control The solenoid valve can be energized manually. The current
concentration value is shown for reference. When the Man. Valve
Control parameter is exited, the valve returns to the closed state.
Note: Press the key to open the valve manually, press the key
to close the valve manually.
Low Standard Valve Enables the Low Standard Valve for manual control.
High Standard Valve Enables the High Standard Valve for manual control.
Stream Valve Note. Single-stream wet-sections only.

Enables the Stream Valve for manual control.
Stream Valve 1 – 3 Note. Multi-stream wet-sections only.

Enables the selected Stream Valve for manual control.
Regeneration Valve If fitted, enables the Regeneration Valve for manual control.
Reset to Defaults Resets all wet-section parameters to their default values. Disabled
Navigator 500
7.1.3 Device Setup
Menu This level is used to access standard setup parameters.

Device Setup
Exit Select

Initial Setup
Instrument Tag A 16-character alphanumeric device (transmitter) identification tag Navigator
displayed in the title bar on all Operator pages.
Temperature Units Selects the temperature units displayed (°C or °F). °C
Reset to Defaults Resets the configuration to the factory default settings.
Security Setup Security access levels are provided, each protected by a password of
up to 6 alphanumeric characters.
Calibrate Password Provides access to Calibrate level only.
(Not factory-set.)
Advanced Password Provides access to all configuration parameters.
(Not factory-set.)
Reset Passwords Clears all passwords.
Range Change Setup Notes.
 Displayed only if 1 single-stream wet-section is connected.
 Range 3 must always be the largest range, Range 1 must always
be the lowest.
 Range Changing is disabled automatically when the sensor type
is changed.
Range Change When Enabled, Analogue Output 2, Relays 3 and 4 are configured Disabled
automatically for range changing and are not available via the
Input/Output sections.
Range 1 Span For correct operation, Range 1 Span should be the lowest range and
Range 2 Span Range 3 Span should be the highest range.
Range 3 Span
When Enabled – the following zero and span ranges 1 to 3 are set
automatically:
Range Zero Span
1 0 100
2 0 1000
3 0 10000
The range spans can be changed to suit end-user’s requirements.
Navigator 500
…Range Change Setup Analog output operation

Analogue output 2 is used for the range changing functionality and is
scaled depending on the range selected. The mA range is set
automatically to 4 to 20 mA.
Analog output 2
Range Zero Span
1 0 % of mA range 100 % of mA range

Note. When range changing is enabled, the Analog Output 2
parameter option in the Input / Outputs level is not available –
see Section 7.1.5, page 52.
Relay operation
Relays 3 and 4 are used for the range changing functionality.
Connect Relay 3 – N/O to Relay 4 – COM
The range selection outputs can be determined as shown in the
following table:
Range Voltage-free contact
1 Relay 3 – N/C Relay 3 – COM

2 Relay 4 – N/C Relay 3 – COM
3 Relay 4 – N/O Relay 3 – COM
SK1
COMMUNICATIONS
RS485 SMART SENSOR

CM40/0215 ISS.1 CM40/0235
MODULE
COM
COM
N/C
N/C
+
–
+
–
SK4 SK5
SK5

5 6
SK2
FUSE RATING
SCREEN
GREEN
BLACK
~100 – 240V
WHITE
RED
3.15A (T)
50/60 Hz
I/O MODULE 2 I/O MODULE

I/O MODULE 33
DIO COM
DIO1
DIO2
DIO3
DIO4
DIO5
DIO6
COM
COM
COM
COM
+24V
N/C
N/C
N/C
N/C
+ – + –
N/C
N/C
N/C
N/C
INT
1 2 3 4 5 N L
COMMS OUT 1 OUT 2

COM
COM
N/O
N/O
N/C
N/C
Relay 3 Relay 4
Note. When range changing is enabled, Relay 3 and 4 parameter

options in the Input / Outputs level are not available –
see Section 7.1.5, page 52.
Navigator 500
7.1.4 Display
Menu Used to select the display language, setup Operator page templates (1 to 5), enable diagnostic,
view and log functions, set the device’s display brightness / contrast and set the time and date.
Display
Exit Select
Language Selects the display language: English

English / German / French / Italian / Spanish.
Operator Templates Enables a template to be assigned to a wet-section for display Page 1

purposes – refer to Section 6.5, page 31 for Operator Template
examples.
Page 1 (to 5) Template Page 1 template cannot be set, this defaults to the number of
wet-sections connected.
Chart View The chart can be configured to display the trend for 1, 2, 3 or 4 PV
and / or temperature values. The engineering ranges for the values
are configured in the Sensor Setup menu – see page 46.
Note: This menu is displayed only when Chart View is Enabled at the
Operator Functions / Chart View.
Channel 1 (to 4)
Source Selects the signal (PV and temperature) to be displayed on the chart.
Tag A 3-character, alphanumeric tag used to identify the parameter on

the chart.
Chart Duration Selects the chart duration from 1, 2, 4, 8, 12, 16, 20 and 24 hours.
View/Log Enables Enables / disables the following View and Log functions:
View functions:
Diagnostics View / Signals View / Chart View / Alarm View / Analog
OP View – refer to Section 6.6, page 33 for examples of Operator
Pages in View mode.
Log functions:
Calibration Log / Alarm Log / Audit Log / Diagnostics Log – refer to
Section 6.7, page 34 for examples of Operator Pages in Log mode.
Navigator 500
…Menu Comment Default
Settings Sets the following display parameters.
Brightness Increases / decreases the device’s brightness settings to suit local

environmental conditions.
Contrast Increases / decreases the device’s contrast settings to suit local

environmental conditions.
Date & Time Sets / formats the device’s date, local time and daylight saving start /
end times:
Date Format DD–MM–YYYY / MM–DD–YYYY / YYYY–MM–DD. DD-MM-YYYY
Date & Time Sets the device date and time in the format: (date format set at Date 01.01.2000
Format menu) XX–XX–XXXX / time (fixed format) HR:MINS:SEC.
Daylight Saving Sets the daylight saving parameters. Off
DS Region Selects the geographical region daylight saving hours are based on:
 Off – daylight saving is disabled.
 Europe – selects standard daylight saving start and end times
automatically.
 USA – selects standard daylight saving start and end times
automatically.
 Custom – used to set custom daylight saving start and end times
manually for regions other than Europe or USA.
Note: The DS Start Time / Occur / Day / Month and Time menus
(below) are activated only when Custom is selected at the DS
Region menu.
DS Start Time Sets the daylight saving start time and end time, selected from
DS End Time 1-hour increments.
DS Start Occur Selects the day within the month that daylight starts / ends – for
DS End Occur example, to set daylight saving to start (or end) on the second
Monday of the selected month, select Second.
DS Start Day Sets the day of the month daylight saving starts / ends.
DS End Day
Note: The DS Start Occur / DS End Occur parameters must be
valid within the month for the selected day.
DS Start Month Sets the month daylight saving starts / ends.

DS End Month
Navigator 500
7.1.5 Input/Output
Menu Input/Output level enables configuration of analog outputs, digital inputs and outputs and relays.
Input/Output
Exit Select
Analog Outputs The analog outputs can be configured to retransmit the process
variable and temperature values and have a configurable range from 0
to 22 mA.
Analog Output 1 to 4 Analog Outputs 3 and 4 are available only if an option board is fitted –
see page 18.
Source Selects the analog signal to be assigned to the output – None

see Table 7.1, page 58.
Output Type Selects the output type required: Linear

 Linear
 Log 2 Decades
 Log 3 Decades
 Log 4 Decades
Elec Low The maximum and minimum engineering range output value 4 mA
Elec High (0 to 22 mA range). 20 mA
Eng Low The maximum and minimum engineering range output value. 0
Eng High 10,000
If the Output Type selection is logarithmic the Eng Low value is set
automatically to 2, 3 or 4 decades below the Eng High value.
Output Failure When enabled, the current output can be driven to a preset value if a Enabled
Failure category diagnostic state occurs for the selected source – see
page 72.
Failure Current Sets a preset value the current output is driven to when a Failure 22.0
category diagnostic state is present. – see page 72.
Note: Active only if Output Failure is Enabled.
Navigator 500
…Menu Comment Default
Digital I/O See page 18 for digital I/O connections.
Digital I/O 1 to 6 Sets the polarity of the input or output signal
Type Sets the Digital I/O to operate as an output or an input: Off

Off – no action taken.
Output – the Digital I/O operates as an output.
Volt Free – high input detected when volt-free switch across input is
closed.
24 Volt – digital input low <5 V, high> 11 V (maximum input 30 V).
Source Selects the digital signal to be assigned to the output – None

Polarity Sets the polarity of the output signal. Non Inverted

Inverted – for an output, if the source is active the output is low. For an
input, if a high signal is detected the input is inactive.
Non Inverted – for an output, if source is active the output is high. For
an input, if a low signal is detected the input is inactive.
Relays
Relay 1 to 6 Relays 5 and 6 are available only if an option board is fitted – see
page 18.
Source Selects the digital signal to be assigned to the relay – None

Polarity Sets the polarity of the relay: Non Inverted

Inverted – if the source is active the relay is energized.
Non Inverted – if the source is inactive the relay is energized.
Navigator 500
7.1.6 Process Alarm
Menu Used to configure up to 8 independent process alarms.

Process Alarm
Exit Select

Alarm 1 to 8
Source Selects the analog value for the process alarm source. None
Type Selects the alarm type from: High Process
 High Process
 Low Process
 High Latch
 High Latch
Tag The alarm Tag is displayed as a diagnostic message and appears in the Alarm <n>
Diagnostic Status Bar and on the Diagnostic View page at Operator level –
see page 31.
Trip The alarm trip level in engineering units. 0.0
Hysteresis The hysteresis trip level in engineering units. Activated at the alarm trip level 0.0
but deactivated only when the process variable has moved into the safe
region by an amount equal to the hysteresis value – see Process alarm
examples below.
Time Hysteresis If an alarm trip value is exceeded, the alarm does not become active until 0
the Time Hysteresis value has expired. If the signal goes out of the alarm
condition before the Time Hysteresis has expired, the hysteresis timer is
reset.
Process alarm examples
Hysteresis
Trip point
Hysteresis
Process variable
Alarm on
High process
Alarm off Alarm on
Low process Alarm off
Fig. 7.2 High and low process alarm action
Process Variable
Trip point Trip point
Hysteresis Hysteresis
Process
variable Alarm on Alarm latched Alarm On Alarm latched
Alarm acknowledged by operator Alarm off Alarm acknowledged by operator Alarm off
High latch alarm Low latch alarm
Fig. 7.3 High and low latch alarm action
Navigator 500
7.1.7 Media Card
Menu Used to set the card on / off status, select the process data to be logged, enter file configuration
selection and save details and to format the media card.
Media Card
Media Card level menus are enabled only if an optional media card module is fitted.
Exit Select
Card Status Selects card status, Online / Offline. Online
Process Data
Channel 1 to 6 Selects the source to be logged – refer to Section 7.2, page 58 for
sources.
Sampling Time Selects the sampling duration time: 5s

5 / 10 / 30 seconds
1 / 5 / 10 / 30 minutes
1 hour
Data Logging Enabled / Disabled data logging. Enabled

In Enable mode data can be written to internal / external media.
In Disable mode, data is prevented from being written to internal /
external media.
Save Configuration
Select File Name (8) Enables a user-selected filename to be specified for the current
configuration to be saved.
Load Configuration
Select File (8) Selects the configuration file to be loaded from a list of previously
saved files.
Quick Format Disabled / Enabled. Disabled

Runs a quick format routine on the SD card / USB stick inserted into
the transmitter’s card reader.
Navigator 500
7.1.8 Communication
Menu Communication level menus are enabled only if an optional communications module is fitted.
Communication Ethernet and Email menus enabled only if a Ethernet communications module is fitted.
Exit Select

Profibus
Slave Address Sets the device-specific slave address for identification on the network.
Baud Rate A read-only value (range 0 to 12000 K) taken from the PC the network
is connected to.
Ethernet
DHCP Sets DHCP (Dynamic Host Control Protocol) on / off.
Set to On if the IP address is to be allocated dynamically by the
network.
Set to Off if the IP address is defined statically.
IP Address Sets the IP address to be assigned to the wet-section. The IP address
is used by the TCP/IP protocol to distinguish between different
devices.
The address is a 32-bit value expressed with 4 values (0 to 255), each
separated by a period (.).
Note. Configurable only if DHCP is disabled.
Subnet Mask The subnet mask is used to indicate which part of the IP address is
used for the network ID and which part is used for the host ID.
Set each bit that is part of the network ID as '1's, for example:
255.255.255.0 indicates the first 24 bits are for the network ID.
Default Gateway Sets the IP address for the Default Gateway (router or switch) used to 000.000.000.000
communicate with other networks.
Note. This setting is required only if a router (or switch) is used.
Email
SMTP Server ID The IP (Internet Protocol) address of the SMTP (Simple Mail Transport
Protocol) server used to distribute emails.
Recipients
Email Address 1 – 3 Enter the email address(es) of the recipient(s).
Triggers
Tag 1 – 4 The trigger description that appears in the subject title.
Source 1 – 4 Up to 4 independently-configurable triggers can be enabled to
generate an email when the selected source becomes active (the email
can be sent to up to 3 recipients).
Invert 1 – 4 If enabled, an email is generated when the Source becomes inactive
instead of active.
Navigator 500
7.1.9 Device Info
Menu Displays read-only factory-set details for the transmitter and connected wet-section(s).
Device Info
Exit Select
Transmitter
Serial Number The transmitter’s serial number.
Date of Manufacture The transmitter’s date of manufacture.
Hardware Revision The transmitter’s hardware version number.
Software Revision The transmitter’s software version number.
Ethernet Enabled only when an Ethernet communications module is fitted –

see page 18.
Ethernet Revision The Ethernet module software version.
MAC Address The Ethernet physical address.
Input/Output
No. Analog Inputs The number of analog inputs available.
No. Analog Outputs The number of analog outputs available.
No. Relays The number of relays available.
Media Card Unit
Software Version The media card unit’s software version number.
Hardware Version The media card unit’s hardware version number.
Sensor 1 – 4
Type The wet-section type(s) connected. Sodium 1 (4)
Serial Number The serial number.(s) of connected wet-section(s).
Date of Manufacture The date of manufacture of connected wet-section(s).
Hardware Revision The hardware version number(s) of connected wet-section(s).
Software Revision The software version number(s) of connected wet-section(s).
Navigator 500
7.2 Analog sources and digital input / output sources

7.2.1 Analog sources
Source name* Description

Low Level D. O. 1 (4)
Hydrazine 1 (4) Measured concentration value for the associated wet-section.
Sodium 1 (4)
Sodium Stream 1 Measured concentration value for stream 1.
Sodium Stream 2 Sodium multi-stream: measured concentration value for stream 2.
Sodium Stream 3 Sodium multi-stream: measured concentration value for stream 3.
Temperature 1 (4) Measured temperature value for the associated wet-section.
Temperature 1 Sodium multi-stream: measured temperature value for stream 1.
Table 7.1 Analog sources
7.2.2 Digital output sources

Alarm 1 (8) State Process alarm state (alarm 1 to 8).
S1 (4) Failure The associated wet-section is in the failed state – see Appendix A, page 72 for possible causes.
S1 (4) Out of Spec. The associated wet-section is out of specification – see Appendix A, page 72 for possible causes.
S1 (4) Maintenance The associated wet-section requires maintenance – see Appendix A, page 72 for possible causes.
S1 (4) Function Check The associated wet-section requires checking – see Appendix A, page 72 for possible causes.
Tx Failure The transmitter is in the failed state – see Appendix A, page 72 for possible causes.
Tx Out of Spec. The transmitter is out of specification – see Appendix A, page 72 for possible causes.
Tx Maintenance The transmitter requires maintenance – see Appendix A, page 72 for possible causes.
Tx Function Check The transmitter requires checking – see Appendix A, page 72 for possible causes.
S1 (4) Cal in Progress A calibration is in progress for the associated wet-section.
S1 (4) Cal Failed The last calibration has failed for the associated wet-section.
Table 7.2 Digital output sources
7.2.3 Digital input sources

S1 (4) High Std Cal High standard calibrations.
S1 (4) Low Std Cal Low standard calibrations.
S1 (4) 2-Pt Cal Two-point calibrations.
S1 (4) 2-Regen Cal A sensor regeneration sequence is followed automatically by a two-point calibration.
S1 (4) Hold The measured concentration for the associated wet-section can be held via the digital input.
Note. It is recommended that a momentary switch is used to start or abort calibrations and a toggle switch is used for the hold
functionality.
To start a calibration – hold the momentary switch for a minimum of two seconds; when the calibration starts release the switch.
To abort a calibration – hold the momentary switch for a minimum of two seconds; when the calibration aborts release the switch.
Table 7.3 Digital input sources
*(4) = maximum number of wet-sections if multiple wet-sections are connected.
Navigator 500
Sodium analyzer 8 Maintenance
8 Maintenance
8.1 Chemical solutions 8.1.2 Standard solutions
The reagents and calibration solutions detailed in this section The following instructions refer to the preparation of 100 µg l-1
are required to keep the wet-section operating. Solutions should and 1 mg l-1 sodium, STANDARD SOLUTION 1 (LOW) and 2
be stored in plastic bottles and, where possible, should be (HIGH) respectively. Alternative concentrations can be prepared
freshly made. within the measuring range selected by appropriate dilution of
the stock solution.
8.1.1 Reagent solutions
Two alternative reagent solutions may be used, depending on It is not advisable to prepare static sodium solutions of less than
the required lower limit of measurement. Concentrated 50 µg l-1 because low concentration solutions rapidly become
ammonia solution, that provides adjustment of sample pH to a contaminated and change in concentration.
minimum of 10.7 (if fresh 35 % w/v ammonia solution is used) is Although the HIGH and LOW standard solutions are typically
suitable for measurements of sodium ion to approximately 0.5 one decade apart in sodium concentration, any concentration
µg kg-1. At concentrations below this, hydrogen ion interference difference can be used if the HIGH solution is at least five times
becomes significant and a reagent of di-isopropylamine (DIPA) the concentration of the LOW solution. It is necessary to have a
should be used. This adjusts the sample pH between 11.2 and significant change in electrode output to achieve an accurate
11.5 and enables measurements to be made down to 0.1 µg calibration.
kg-1.
For all practical purposes, ‘µg l-1’ can be considered equal to
1. Concentrated ammonia solution – 1 liter (0.22 US gal.). ‘µg kg-1’ (‘ppb’) and ‘mg l-1’ equal to ‘mg kg-1’ (‘ppm’).
Warning. This reagent must only be handled under a To prepare stock solution (1000 mg l-1 sodium ions):
fume hood. It causes burns and is irritating to the 1. Dissolve 2.543 (±0.001) g of analytical reagent grade
eyes, respiratory system and skin. Wear rubber gloves sodium chloride in approximately 100 ml high purity water.
and eye protection. In warm weather pressure Transfer this solution to a one liter volumetric flask and
increases in the bulk container of ammonia and the make up to the one liter mark with more high purity water
cap must be released with care. to give a stock solution of 1000 mg l-1 sodium ions. Store
in a plastic container.
A 35 % w/v solution (s.g. 0.88) is recommended, but 2. Pipette 10 ml of this solution to a one liter volumetric flask.
lower concentrations, to a minimum of 30 % w/v (s.g. Make up to the one liter mark with high purity water to give
0.89), can be used. a solution of 10 mg l-1 sodium ions.
2. Di-isopropylamine – 1 liter (0.22 US gal.). 3. Pipette 10 ml of the 10 mg l-1 solution into a one liter
volumetric flask and make up to the one liter mark with
Warning. DIPA is an extremely inflammable and high purity water to give the LOW standard solution of
irritating colorless liquid with an ammoniacal odor. 100 µg l-1 sodium ions. Transfer this solution to the bottle
Handle with care at all times. labelled STANDARD SOLUTION 1 (LOW).
The following points must also be noted: 4. Transfer 100 ml of the 10 mg l-1 solution to a one liter
volumetric flask and make up to the mark with high purity
 Avoid breathing vapor and avoid contact with
water to give the HIGH standard solution of 1 mg l-1
skin and eyes.
sodium ions. Transfer this solution to the bottle labelled
 Work under a fume hood, wearing rubber STANDARD SOLUTION 2 (HIGH).
gloves and eye protection.
 Keep away from sources of ignition. Note. High purity water = water containing less than
No smoking 2 µg l-1 sodium ions and a specific conductivity of less than
approximately 0.2 µS cm-1.
 In the event of a fire, extinguish with water spray,
foam, dry powder or carbon dioxide.
8.1.3 Salt bridge solution
 If a spillage occurs, shut off all possible sources This solution is required for refilling the double junction silver /
of ignition and instruct others to keep at a safe silver chloride reference electrode at extended intervals. The
distance. Mop up spillage with plenty of water, solution supplied with the electrode (3.5 M potassium chloride)
diluting greatly. Ventilate the area well to should be used for refilling using the plastic pipette provided.
evaporate any remaining liquid and dispel vapor.
 Effluent from the wet-section contains DIPA (if
this reagent is used). Contact with it should also
be avoided.
Navigator 500
8.2 Scheduled servicing

The following procedures are guides to the maintenance 3. Check sodium concentration.
requirements of the wet-section. The procedure chosen – When the sodium concentration is above 1 µg kg-1,
depends on the particular installation and sample conditions. perform a two-point calibration – see Section 5.5,
8.2.1 Weekly page 24; note the Slope value.
If the wet-section is running continuously at high concentrations – When the sodium concentration is below 1 µg kg-1,
(>100 µg kg-1) perform a weekly single-point calibration – see apply the regeneration procedure automatically or
Section 5.5, page 24. manually – see Section 8.3, page 61 (automatic) or
Section 8.4, page 63 (manual).
8.2.2 Monthly
1. Replace the bottle of reagent solution at regular intervals
(see Fig. 2.1, page 6 for bottle location). If ammonia is Note.
being used, the level of solution should not be allowed to
fall by more than 1/4. Discard the remaining reagent  It is important that this procedure is carried
solution (predominantly water). out at regular 1-monthly intervals and that
the process is started as soon as a new
electrode is put into service.
Note. The frequency at which reagent needs to be
replaced is dependent on the ambient temperature and the  It is extremely difficult to recover an ‘old’
concentration of sodium being measured (for accurate low electrode.
sodium readings, the solution may require replacement
more frequently).
4. Perform a automatic or manual regeneration procedure:
– to perform an automatic regeneration (available only if
2. Refill the reference electrodes using the solution supplied
optional regeneration hardware is fitted), refer to
with the electrode:
Section 8.3, page 61
– for versions with a reservoir, check the level in the
reference electrode reservoir and refill if below 10 mm – to perform a manual regeneration, refer to Section 8.4,
(0.4 in.) – refer to Section 4.1.2, page 20, for filling page 63
instructions.
Note. For information about the regeneration
Referring to Fig. 8.1: solution, contact the local ABB representative.
– for versions without a reservoir, ensure the level of
solution in reference electrode A is above the flowcell
block B. Refill as required.
Fig. 8.1 Checking solution level,

non-reservoir wet-sections
Navigator 500
8.2.3 12-Monthly
1. Check the condition of all plastic tubing; replace it as 8.3 Automatic regeneration
required – refer to Section 8.6, page 65 for multi-stream The regeneration valve is energized for 1 minute. The analyzer
wet-sections or Section 8.7, page 67 for single-stream then starts a 2-hour regeneration recovery period. After the
wet-sections. recovery period a two-point calibration is initiated automatically.
2. Clean the flowcell and the Pt1000 temperature A scheduled regeneration does not commence if the No
compensator to remove any deposits. Samples diagnostic (see Appendix A.1, page 72) is active.
Referring to Fig.8.2: It is not advisable to perform a manual regeneration procedure
(see Section 8.4, page 63) if the No Samples diagnostic is
a. Remove the Pt1000 temperature compensator A by
active.
unscrewing the compensator sleeve B and
withdrawing the Pt1000 temperature compensator
from the flowcell C. Note. If it is detected that no regeneration solution is
present, the regeneration valve is de-energized
b. Clean the Pt1000 temperature compensator A and automatically and a recovery period is initiated. A two-point
flowcell C using high purity water. calibration is initiated after the recovery period.
c. When replacing the Pt1000 temperature compensator,
ensure that the O-ring D is in place below the flange To start an automatic regeneration:
on the compensator, and the skid washer E is in
place above the flange. 1. Press the key (below the icon).
2012–04–15
Tag 1
2.93 ppb
21.7 °C
Na
CAL
The Operator menus are displayed:
2012–04–15
Operator Pages
4.28
Data Views
Logs ppb
Alarm Acknowledge
Manual Hold
Autoscroll 21.7 °C
Media Card
Fig. 8.2 Cleaning the flowcell and Pt1000 temperature Enter Configuration
compensator
2. Press the key to scroll to the Enter Configuration menu

and press the key (below the icon).
Access Level
Read Only
Calibrate
Advanced
Service
Back Select
3. Use the key to scroll to the Advanced access level

and press the key (below the Select prompt) to enter
the top level Configuration menus.
Navigator 500
4. If the Calibrate page is not displayed, use the / 7. Press the key (below the Select prompt).
keys to scroll to the Calibrate page:
The Sensor Calibration page is displayed:
Menu
Sensor Calibration
Calibrate
Low Calibration
High Calibration
Two-Point Cal
Regeneration Cycle
Process Calibration
Exit Select
Back Select

Press the key to highlight the Regeneration Cycle
– If one or more single-stream wet-sections are menu.
connected, the Calibrate / Sodium 1 (2, 3, 4) page is
displayed:
The Regeneration Cycle page is displayed:
Calibrate
Regeneration Cycle
Sodium 1
Start Procedure
Back Select
No Yes
– If a multi-stream wet-section is connected, the
Calibrate / Sodium Three Stream page is displayed: Press the key (below the Yes prompt) to start the
regeneration procedure.
Calibrate
Sodium Three Stream
Back Select

The following page is displayed with the Sensor
Calibration menu selected:
Sensor 1
Sensor Calibration
Calibration Setup
Restore Defaults
Back Select
Navigator 500
8.4 Manual regeneration 8.5 Shut-down procedures

Warning. Observe relevant safety procedures when
1. Carefully unscrew plastic sleeve A a few turns (with handling reagent solutions.
sodium electrode B in place).
2. Withdraw sodium electrode B from the sleeve and 1. Close the sample valve upstream of the wet-section.
flowcell C (it is not necessary to detach the electrode
lead D). 2. Remove the reagent container (see Fig. 2.1, page 6 for
bottle locations) and store or dispose of the solution safely.
3. Remove O-ring E. If disposing, rinse the container thoroughly.
4. Prepare two plastic beakers, one containing about 50 ml 3. Fill the regeneration solution container (if fitted) with high
of etch solution, the other about 200 ml high purity water. purity water and energize the regeneration valve via the
5. Dip the electrode in the etch solution for 60 (±5) seconds Man. Control Valve menu (see Section 7.1.2, page 47) for
then rinse in high purity water. 5 minutes.
4. Fill the calibration solution containers with high purity
Caution. Do not to exceed the etch time or the water and perform a two-point calibration to flush the
electrode’s performance may be permanently wet-section.
degraded.
5. Remove the electrodes and follow storage procedure in
Section 8.5.1.
6. Dispose of the etch solution safely by diluting with plenty
6. Use a syringe to flush all tubing with high purity water. This
of water (use fresh etch solution each time).
removes any particulate deposits.
7. Refit O-ring E, sodium electrode B and screw plastic
7. Switch off the mains supply to the transmitter.
sleeve A finger-tight (do not over-tighten).
8. Run the wet-section for 1 to 2 hours on sodium sample Note. For multiple wet-section installations, do not
before attempting a calibration. switch off the mains supply to the transmitter if
operation of the remaining wet-sections needs to be
continued.
Fig. 8.3 Manual regeneration of sodium electrode
Navigator 500
8.5.1 Preparing the sodium and reference electrodes for

storage
1. Unscrew (but do not remove) plastic sleeve A and
carefully slide sodium electrode B out of the flowcell C.
2. Fill the rubber teat D (supplied with the sodium
electrode) with High Cal solution or typically with 1 mg kg-1
sodium containing a few drops of concentrated ammonia
solution and push the teat over the end of the sodium
electrode.
3. Carefully withdraw reference electrode E from the
flowcell.
4. Fill the rubber teat F (supplied with the reference
electrode) with salt bridge solution and push the teat over
the end of the reference electrode.
5. Refit the filling hole plug G (non-reservoir option) or
H (reservoir option) to seal the refill aperture.
Note. Do not let electrodes dry out.
Fig. 8.4 Preparing the sodium and reference electrodes for

storage
Navigator 500
8.6 Replacing plastic tubing – multi-stream wet-sections

It is recommended that all plastic tubing is replaced every 12 months. Use only the correct size and type of tubing – refer to Fig. 8.5
and Fig. 8.6 (page 66) for tubing location and Table 8.1, page 66 for tubing lengths.
Two sections of tubing are critical:
 tubing (item A) between the reagent container and entrainment ‘T’ piece – this must be a polyethylene-lined tube with good
chemical resistance to the reagent.
 tubing (item J) between the constant-head unit and the entrainment ‘T’ piece – cut 100 mm (4 in.) of the 1 mm ID silicon
rubber tube and fit onto the tube connectors. The tube should be taut to prevent interference with the flow and self-starting
characteristics.
Note. Tubes B, C and D use QD couplings at the solution bottles, all other tubing connections are to barbed connectors.
Entrainment T-piece and

constant-head unit moved forward
for clarity only. Refer to Fig. 2.1,
page 6 for locations within cubicle.
To flowcell
Key to tubing
Multi-stream configuration –
wet-sections without regeneration option. *
Multi-stream configuration –
wet-sections with regeneration option
*For inlet tube routing on wet-sections with flowmeters, refer to item Fig. 8.6, page 66, item M.
Fig. 8.5 Physical arrangement, all plastic tubing – sodium multi-stream wet-section without flowmeters
Navigator 500
*For inlet tube routing on wet-sections without flowmeters, refer to Fig. 8.5, page 65, item M.
Fig. 8.6 Physical arrangement, inlet tubing only – sodium multi-stream wet-section with flowmeters
Length Part number

Item Description Quantity
mm (in.) and size
0212397
A Reagent tubing 550 (21.6) 3 1
/32 in. ID x 5/32 in. OD
B Calibration solution 2 tubing (disconnect QD coupling first) 250 (10) 1*
0212214*
C Regeneration solution tubing (if fitted) – disconnect QD coupling first 250 (10) 1 1*
/16 in. ID x 1/8 in. OD
D Calibration solution 1 tubing (disconnect QD coupling first) 250 (10) 1*
E Constant-head to calibration + regeneration valve assembly 50 (2) 1*
Calibration + regeneration valve assembly to manifold valve assembly
F (same tubing used for optional regeneration / non-regeneration 145 (5.7) 0212362* 1*
3
wet-sections) /32 in. ID x 5/32 in. OD
Tygon
G Regeneration / Calibration 2 / Calibration 1 jumper tubing 50 (2) 2*
H Switching valve to manifold valve 50 (2) 3*
0212189
I Sample outlet tubing 280 (11) 1 1
/4 in. ID x 3/8 in. OD
0212206
J Constant-head to entrainment 'T' piece tubing 100 (4) 1
1 mm ID x 1 mm wall
K Entrainment 'T' piece to flowcell chamber tubing Factory-fitted
1* per
L Drain tubing – same length for wet-sections with / without flowmeters 145 (5.7)
stream
Inlet tubing, streams 1 to 3 – wet-section without flowmeters 145 (5.7) 1*
0212362*
(see Fig. 8.5, page 65) 3 per inlet
/32 in. ID x 5/32 in. OD
M Inlet tubing – wet-section with flowmeters (see Fig. 8.6): Tygon
Stream 1 145 (5.7) 1*
Stream 2 190 (7.5) 1*
Stream 3 245 (9.6) 1*
Table 8.1 Schedule of replacement of plastic tubing – multi-stream sodium (3-stream)
*Tubing must be cut to correct length.
Navigator 500
8.7 Replacing plastic tubing – single-stream wet-sections

It is recommended that all plastic tubing is replaced every 12 months. Use only the correct size and type of tubing – refer to Fig. 8.7
for tubing location and Table 8.2, page 68 for tubing lengths.
Two sections of tubing are critical:
 tubing (item A) between the reagent container and entrainment ‘T’ piece – this must be a polyethylene-lined tube with good
chemical resistance to the reagent.
 tubing (item I) between the constant-head unit and the entrainment ‘T’ piece – cut 100 mm (4 in.) of the 1 mm ID silicon
rubber tube and fit onto the tube connectors. The tube should be taut to prevent interference with the flow and self-starting
characteristics.
Note. Tubes B, C and D use QD couplings at the solution bottles, all other tubing connections are to barbed connectors.
Entrainment T-piece and

constant-head unit moved forward
for clarity only. Refer to Fig. 2.1,
page 6 for locations within cubicle.
To flowcell
Key to tubing
Single-stream configuration –
wet-sections without regeneration option.
Single-stream configuration –
wet-sections with regeneration option
Fig. 8.7 Replacement of plastic tubing – single-stream sodium
Navigator 500
Item Description Length mm (in.) Part number Quantity
0212397
A Reagent tubing 550 (21.6) 3 1
/32 in. ID x 5/32 in. OD
B Calibration solution 2 tubing (disconnect QD coupling first) 250 (10) 1*

0212214*
C Regeneration solution tubing (if fitted) – disconnect QD coupling first 250 (10) 1 1*
/16 in. ID x 1/8 in. OD
D Calibration solution 1 tubing (disconnect QD coupling first) 250 (10) 1*
E Constant-head to calibration + regeneration valve assembly 50 (2) 1
Calibration + regeneration valve assembly to switching valve assembly 0212362*

F – same tubing used for optional regeneration / non-regeneration 145 (5.7) 3
/32 in. ID x 5/32 in. OD 1*
wet-sections Tygon
G Regeneration / Calibration 2 / Calibration 1 jumper tubing 50 (2) 2*
0212189
H Sample outlet tubing 280 (11) 1 1
/4 in. ID x 3/8 in. OD
0212206
I Constant-head to entrainment 'T' piece tubing 100 (4) 1
1 mm ID x 1 mm wall
J Entrainment 'T' piece to flowcell chamber tubing Factory-made
K Drain tubing – same length for wet-sections with / without flowmeters 145 (5.7) 0212362* 1*
3
Inlet tubing – same length for single-stream wet-sections with / /32 in. ID x 5/32 in. OD
L 145 (5.7) Tygon 1*
without flowmeters
Table 8.2 Schedule of replacement of plastic tubing – single-stream sodium
*Tubing must be cut to correct length.
Navigator 500
Sodium analyzer 9 Specification – analyzer
9 Specification – analyzer
Operation Environmental data
Measuring range Ambient operating temperature:
0.01 to 10,000 ppb 0 to 55 ºC (32 to 131 ºF)
Units of measure Ambient operating humidity:
ppb, µg/l, µg/kg Up to 95 % RH non-condensing
Accuracy Storage temperature:
±5 % of reading or ±0.1 ppb, whichever is the greater (applies only – 20 to 70 °C (–4 to 158 °F) without sensor
when sample is within ±5 °C of calibration temperature) 0 to 55 °C (41 to 131 °F) with sensor
Repeatability
±5 % of reading or ±0.1 ppb, whichever is the greater (applies within
Approvals, certification and safety
a ±5 °C [±9 °F] variation)
CE mark
Response time
cULus
1 to 100 ppb <4 mins;
General safety
100 to 1 ppb <4 mins for a 90 % step change
EN61010-1
Multi-stream measurement
Pollution degree 2
Sample time programmable between 10 and 60 min.
Insulation class 1
Resolution
0.001 ppb
Temperature compensation EMC
5 to 55 °C (41 to 131 °F) automatic using a Pt1000 Emissions & immunity
AutoCal frequency Meets requirements of IEC61326 for an industrial environment and
Programmable from 1 to 7 days or 1 to 8 weeks domestic emissions
Sample temperature
5 to 55 °C (41 to 131 °F) Maintenance
Sample pressure Periodic calibration:
1.5 bar gauge (21.7 psi) maximum User-defined
Sample flow rate
100 to 400 ml/min DS/ASO550–EN Rev. E
Sample connections
1
/4 ID flexible tubing to barbed connector
Navigator 500
Sodium analyzer 10 Specification – transmitter
10 Specification – transmitter
Operation Relay outputs
Display 4 standard
89 mm (3.5 in) color 1/4 VGA TFT, liquid crystal display (LCD) with 2 optional
built-in backlight and brightness / contrast adjustment
Fully-programmable. Contacts rated at 2A @ 110 / 240 V. Standard
Language relays are changeover. Optional relays are normally closed (N/C).
English, German, French, Italian, Spanish
Keypad
6 tactile membrane keys:
Digital inputs / outputs
6 standard, user-programmable as input or output
Group select / left cursor, view select / right cursor, menu key,
up, down, enter key Minimum input pulse duration: 125 ms
No of inputs Input – volt-free or 24 VDC (conforms to IEC 61131-2)
Up to 4 single-stream or 1 multi-stream wet-section Output – open-collector, 30 V, 100 mA max.
(conforms to IEC 61131-2)
Mechanical data
Protection Connectivity / communications
IP66 / NEMA 4X Ethernet (optional)
Dimensions TCP/IP, HTTP
Height – 194 mm (7.64 in) minimum (excluding glands)
Width – 214 mm (8.42 in) – excluding glands Data logging
Depth – 98 mm (3.85 in) door closed – minimum (excluding fixing Storage
brackets) Measurement value storage (programmable sample rate)
Weight – 1.5 kg (3.3 lb) Audit Log*, Alarm Log*, Calibration log, Diagnostics log,
Materials of construction Configuration changes
Glass-filled polycarbonate Chart view
On local display
Historical review
Security
Of data
Password protection
Data transfer
Calibrate and Advanced – user-assigned
Service level access – factory-set Secure digital (SD) card interface / USB stick – Windows-compatible
FAT file system, data and log files in Excel and DataManager Pro
compatible formats
Electrical
*Audit Log and Alarm Log data are stored in the same log file.
Power supply ranges
100 to 240 V AC max., 50 / 60 Hz ± 10 %
(90 to 264 V AC, 45/65 Hz) DS/ASO550–EN Rev. F
Power consumption
<10W
Terminal connections rating

AWG 26 to 16 (0.14 to 1.5 mm2)
Analog outputs
2 standard
2 optional
Galvanically isolated from the rest of the circuitry, 500 V for 1 minute.
Range-programmable source and range 0 to 22 mA, maximum
load 750  @ 20 mA
Navigator 500
Sodium analyzer 11 Specification – wet-section
11 Specification – wet-section
Mechanical data
Protection
IP54
Dimensions
Height – 668 mm (26.30 in), including solution bottles
Width – 290 mm (11.41 in) – door shut
Depth – 185 mm (7.28 in) door closed – minimum
(excluding fixing brackets)
Weight – 4.5 kg (10 lb)
Electrical
Power supply ranges (supplied by transmitter)
24 V DC max.
Power consumption
8 W max.
DS/ASO550–EN Rev. E
Navigator 500
Sodium analyzer Appendix A – Troubleshooting
Appendix A – Troubleshooting
A.1 Diagnostic messages
The transmitter is programmed to display diagnostic messages Diagnostic Icon NAMUR Status
to provide information on servicing requirements and any other
conditions that develop during operation. Failure
All diagnostic messages displayed on the transmitter are added
to the transmitter's Audit Log.
Check function
The tables below show icon types, diagnostic messages and
possible causes / suggested remedial action.
Out of specification
Note. The diagnostic icons in the following tables conform
to NAMUR 107.
Maintenance required
Icon Diagnostic message Possible cause and suggested action
Wet-section failure (temporary or permanent failure of analog to digital converter for wet-section 1, 2, 3, 4).
ADC Failure
(S1, S2, S3, S4) Cycle power to the transmitter.
If problem persists replace electronics inside wet-section, contact local service organization.
The wet-section is drawing more current than available.

The power being drawn from the transmitter exceeds the maximum permitted level.
Excessive Power Check the wiring to all wet-sections connected for possible wiring problems.
Check any digital outputs powered from the +24 V out terminal.
Ensure the limits are not exceeded.
Communication to wet-section failure

Int Comms Error Communication to one or all the wet-sections has failed during cyclic reads.
Check wiring between transmitter and wet-sections.
Sodium multi-stream only

No Samples No samples available (at wet-section).
If a multiple wet-section setup, the transmitter cannot detect any samples flowing into the wet-section.
No Sample No sample available (at wet-section).

(S1, S2, S3, S4) Check sample flow rates are >50 ml/min.
NV error – comms. board (CRC Comms.)

Failure of non-volatile memory on communications board or permanent corruption of its data.
NV Error Comm Bd Cycle power to the transmitter.
If problem persists check all configuration parameters and correct any errors.
If problem still persists contact local service organization.
NV error – main board (CRC Comms.)

Failure of non-volatile memory on main board or permanent corruption of its data.
NV Error Main Bd Cycle power to the transmitter.
NV error – processor board (CRC Comms.)

Failure of non-volatile memory on processor display board or permanent corruption of its data.
NV Error Proc Bd Cycle power to the transmitter.
If problem still persists contact local service organization
Failure of wet-section (1, 2, 3, 4) non-volatile memory or permanent corruption of its data.

NV Error Cycle power to the transmitter.
(S1, S2, S3, S4) If problem persists check all configuration parameters for all wet-sections and correct any errors.
Table A.1 Diagnostic messages (Sheet 1 of 3)
Navigator 500
NV error – software key 1 (CRC Comms.)

Failure of non-volatile memory on software key 1 board or permanent corruption of its data.
NV Error SW Key 1 Cycle power to the device.
Temperature sensor failure for wet-section1 (2, 3, 4).

Temp Failure
The temperature compensator or associated connections are either open-circuit or short-circuit.
(S1, S2, S3, S4)
Check wiring temperature compensator connections to the PCB.
Calibrating.
Calibrating
Displayed during calibration of wet-section (1, 2, 3, 4).
(S1, S2, S3, S4)
On a multiple wet-section setup, this inhibits other wet-sections being calibrated.
Wet-section (1, 2, 3, 4) in manual hold mode via front panel.

In Hold Mode
Analog outputs and alarms are held.
(S1, S2, S3, S4)
To exit manual hold press the key, scroll to Manual Hold and select the appropriate wet-section(s).
Wet-section(s) performing a recovery stage after calibration, regeneration, or after exiting Man.Valve Control –
Recovery
see page 47.
(S1, S2, S3, S4)
During the recovery period, outputs and alarms are held if Hold Outputs is enabled – see page 45.
A regeneration routine is being run.

Regeneration
Refer to Section 5.7, 28 for details of this routine.
Simulation On The analyzer is operating in Simulation mode.
Last wet-section calibration failed.

Cal.Failed
Check reagent is entraining (bubbles at end of entrainment tube, check reagent is fresh).
(S1, S2, S3, S4)
Check the calibration solution.
Flow Error
(S1, S2, S3, S4) Sample flow rate is less than 50 mlmin.(3.05 cu in.min.)
Displayed only if Increase the sample flow to the wet-section.
flowmeter is fitted
Memory card is full, no more data can be saved to the card.

Media Card Full
Replace memory card.
Missed Cal.
Missed last schedule calibration.
(S1, S2, S3, S4)
PV Range Process value (PV) measured is out of the specified range of the wet-section.
(S1, S2, S3, S4) 0 to 10,000 ppb.
Sample Cold Sample solution temperature lower than 5 °C (41 °F).

(S1, S2, S3, S4) Increase the temperature of the sample.
Sample Hot Sample solution temperature higher than 55 °C (131 °F).

(S1, S2, S3, S4) Reduce the temperature of the sample.
Navigator 500
Memory card is more than 90% full.

Media Near Full
Replace memory card.
Out of low calibration solution.

No Low Cal Replace low calibration solution and start a calibration.
(S1, S2, S3, S4)
Note. Displayed only if Solution Detection is enabled.
Out of high calibration solution.

No High Cal Replace high calibration solution and start a calibration.
(S1, S2, S3, S4)
Note. Displayed only if Solution Detection is enabled.
Out of regeneration solution.

No Regen.Sol Replenish solution.
(S1, S2, S3, S4)
Note. Displayed only if regeneration hardware is fitted and solution detection is enabled.
Sodium multi-stream only

No Sample
No sample available at wet-section.
(S1, S2, S3, S4)
Check sample flow rates are >50 ml/min.
Navigator 500
A.2 Calibration pass and fail limits

After a two point calibration, the percentage Slope is calculated. Percent slope Action
The calibration pass limits and their meanings are shown
in Table A.2. Slope > 110 % Calibration unacceptable.
New coefficients ignored and the transmitter
Any unexpected results may be due to the standard or reagent continues to use the last known good
solutions. If doubts exist about the integrity of these solutions, coefficients.
replace them with freshly prepared solutions in the early stages Check correct calibration standards have
of the fault-finding investigations. been used.
Check the correct calibration standard
The accuracy of the wet-section is affected by the condition of values have been entered into the
all the solutions involved, one or more of which can be transmitter.
incorrectly made or contaminated.
80 % <Slope <110 % Calibration acceptable.
Measuring the pH of the effluent from the flowcell indicates the New coefficients are used saved and the
amount of buffering of the sample. The minimum pH depends transmitter uses these values for
on the minimum sodium concentration, but the pH value is subsequent calculations.
calculated as shown below.
Slope < 80 % Calibration unacceptable.
pH must be greater than pNa + 3, so ideally at: New coefficients are ignored and the
transmitter continues to use the last known
100 µg kg-1 Na+, the pH must be greater than 8.4
good coefficients.
10 µg kg-1 Na+, the pH must be greater than 9.4 Check the correct calibration standards
have been used.
1 µg kg-1 Na+, the pH must be greater than 10.4 Check the correct calibration standard
0.1 µg kg-1 Na+, the pH must be greater then 11.4 values have been entered into the
transmitter.
If solutions are satisfactory, replace the
Note. If the reagent is allowed to become completely electrode pair.
exhausted, the reading may be very erratic due to the lack
Table A.2 Calibration pass limits
of ionic strength adjustment of the high purity sample.
Check mechanical components involved with liquid handing

systematically for leaks or blockages as they change the
chemical conditions around the electrode. Most problems are
found to be associated with the chemistry, electrodes and the
liquid handling section.
Navigator 500
A.3 Checking the temperature input A.4 Incorrect or erratic flow rate readings
1. Check that the wet-section responds to a temperature Incorrect or erratic flow rate readings may be due to a blockage
input. Disconnect the Pt1000 temperature compensator in the flowmeter. Stop the flow of sample to the wet-section,
leads in the wet-section PCB (see Section 3.4.3, page 15) remove the flowmeter and back-flush it with water or air. Re-
and connect a suitable resistance box to the wet-section connect the flowmeter, start the sample flow and check the flow
PCB inputs. reading. If the problem persists a replacement flowmeter may be
required – see page 82.
Note. Resistance boxes have an inherent residual
resistance which may range from a few milliohms up A.5 Erratic sodium readings
to 1 ohm. This value must be taken into account when If the sodium reading appears noisy/erratic carry out the
simulating input levels, as should the overall tolerance following checks:
of the resistors within the box.  check the entrainment of reagent is regular and not
intermittent
2. Check that the transmitter displays the correct values as  check the reagent has not become exhausted – either
set on the resistance box – see Table A.3. Incorrect check the pH of the sample exiting the flow cell (see
readings usually indicate an electrical calibration problem. Section A.2, page 75 for ideal pH values) or install a fresh
bottle of reagent solution.
Temperature °C (°F) Resistance 
 check the flow cell stud terminal (Fig. 2.1, page 6) is
0 (32) 1000.0 connected securely to a suitable earth (for example, the
earth stud on the transmitter).
10 (50) 1039.0
20 (68) 1077.9
30 (86) 1116.7
40 (104) 1155.4
50 (122) 1194.0
60 (140) 1232.4
Table A.3 Temperature readings for resistance inputs
3. If the readings checked at step 2 are correct, perform a

resistance check on the Pt1000 temperature
compensator and confirm the values are as shown in
Table A.3.
4. If the readings are still incorrect, check the connector
block cable connections at the wet-section PCB and their
condition.
Navigator 500
Sodium analyzer Appendix B – Multi-stream sodium wet-section
Appendix B – Multi-stream sodium wet-section

The sample streams enter the bottom of the wet-section (via flow meters if fitted), diverting sample to the sample valve manifold
(mounted on the top of the bracket) and the calibration valve manifold to the constant-head unit. The solenoid valves are used to
switch between sample streams. If a stream valve is energized the sample flows up to the constant-head unit via the manifold and is
measured by the wet-section. If a stream valve is de-energized the sample is diverted directly to drain.
The sample time is the duration of time between the stream valve energizing and the corresponding stream value updating on the
transmitter. Between updates the reading on each stream is held. The sample time is the same duration for all streams. The sample
time is normally set to 15 minutes, but may need to be increased if the difference is sodium concentration between streams is
significant or if an accurate low concentration reading is required. Table B.1 shows suggested sample times for different sodium
concentrations.
Sodium concentration: Sodium concentration: Recommended sampling Upscale / Downscale

previous stream (ppb) current stream (ppb) times (minutes) change
0.1 5 20 Upscale
0.1 50 15 Upscale
5 50 10 Upscale
50 50 10 Upscale
5 0.1 35 Downscale
50 0.1 40 Downscale
50 5 10 Downscale
500 50 10 Downscale
Table B.1 Recommended sample times for sodium concentration values
The stream sequence is normally set to sample each stream in turn – for example, on a three stream wet-section the sequence would
be set to 1, 2, 3. However, greater priority could be given to a particular stream (for example, stream 1) by programming the
sequence 1, 2, 1, 3 or 1, 1, 1, 2, 3.
If only 1 stream is enabled the wet-section functions as a single-stream version and continuously measures the sodium
concentration. This is useful for troubleshooting as there is a concentration update every second.
B.1 Multi-stream with flowmeters fitted

The flow rate measurements are used by the wet-section PCB to determine whether there is enough sample flow to measure each
stream – it is advisable to ensure at least 100 ml/min of sample is supplied to each stream. The wet-section does not sample a
stream if the flow rate drops below 50 ml/min.
If the sample flow rate is measured to be less than 50 ml/min, the Flow Error diagnostic activates for that stream (see page 73). If the
sample flow rate drops below 50 ml/min while the stream is being sampled, the concentration value is not updated and the wet-
section starts to sample the next available stream in the stream sequence.
If all streams are below the required flow rate of 50 ml/min, the No Samples diagnostic is displayed (see page 74). This situation
should be avoided. If the wet-section is going to be without sample for extended periods the Shutdown Procedure should be
followed – see Section 8.5, page 63.
B.2 Multi-stream with no flowmeters fitted

If during the sampling period the stream is detected to be Out of Sample via the Out of Solution pressure switch, the No Sample
diagnostic activates for that stream, the stream valve is de-energized and the stream value is not updated (see Appendix A.1,
page 72). The next enabled stream in the stream sequence is then sampled.
If all streams are detected to have no sample the No Samples diagnostic is displayed and the wet-section searches for an available
stream. This procedure energizes each valve in the stream sequence for up to 14 seconds; this continues until a stream is detected
to be in sample, it then continues to sample that available stream. The No Samples situation should be avoided. If the wet-section is
without sample for extended periods, follow the shutdown procedure – see Section 8.5, page 63.
Navigator 500
Sodium analyzer Appendix C – Multiple wet-section setup
Appendix C – Multiple wet-section setup

A single Navigator 540 transmitter can monitor up to 4 wet-sections. The wet-sections can be any combination of the three Navigator
500 parameters – sodium, low level dissolved oxygen and hydrazine. Note that the transmitter cannot monitor more than 1 wet-
section if the wet-section is a multi-stream sodium.
If an additional wet-section is added to a transmitter, the procedures in Sections C.1 and C.2 must be performed.
C.1 Configuring the device address

The unique device address assigned to the wet-section (1 to 4), enables the transmitter to identify the wet-section on the data
transmission link. Each wet-section must have its own unique address. The address can be set by SW1 as shown in Table C.1 and
Fig. C.1. LEDs D4 and D5 indicate the slave address of the PCB.
Slave address SW1.1 SW1.2 LED D4 LED D5
1 OFF OFF OFF OFF
2 OFF ON OFF ON
3 ON OFF ON OFF
4 ON ON ON ON
Table C.1 Configuring the device address
Terminals G and W
SW1.1 SW1.2
OFF position ON position
ON
B R Scr 1 3 5 7 9 1 1 13 15 17 19 21 23 25 27 29 31 33 3
G W 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
1 2
SW1
SW1
1 2
ON
D5
D4
Configuration DIP switch SW1
LED D4 and LED D5
Fig. C.1 Configuration DIP switch SW1 and LED D4 / D5 location
C.2 Serial connections

Each wet-section must be connected in a 'daisy chain' format as shown in Fig. C.2.
Navigator 500 Wet-section 1 Wet-section 2 Wet-section 3 Wet-section 4

R R R R
Red
B B B B
Black
G G G G
Green
W W W W
White
SCR SCR SCR SCR
Screen
Fig. C.2 Serial connections
Note. The total cable length between the transmitter and the last wet-section must not exceed 30 m (98 ft.).
Navigator 500
Sodium analyzer Appendix D – Spare parts and consumables
Appendix D – Spare parts and consumables

D.1 Navigator 500 sodium consumables D.2 Navigator 500 sodium wet-section spares
Part No. / Type Usage / Volume Part No. Description
AWRS5000101 General purpose sodium measurements AW500 040 Flowmeter upgrade kit
for concentrations above 0.5 ppb.
Sodium reagent –
ammonia Provides up to 30 days of continuous
operation.
Shelf life 18 months – also available as a kit
(AWRK5000111, see below).
AWRS5000102 For low level sodium measurements (less

than 0.5 ppb) and cation bed applications.
Sodium reagent –
DIPA Provides up to 8 weeks of continuous AW501 030 ASO550 sodium electrode
operation.
Shelf life 1 year – also available as a kit
(AWRK5000112).
AWRS5000103 Sodium regeneration solution.

Provides approximately 15 automatic
regenerations.
Shelf life 1 year – also available as a kit
(AWRK5000113).
AWRS5000104 Navigator 500 sodium standard –

100 ppb sodium / 1 x 1 liter bottle. AW501 035 ASO550 reference electrode for non reservoir-
fed systems
AWRS5000105 Navigator 500 sodium standard –
1000 ppb sodium / 1 x 1 liter bottle.
AWRK5000111 General purpose sodium measurements.

Sodium reagent kit 6 x 1 liter bottles of ammonia solution
– ammonia (AWRS5000101).
Provides up to 6 months operation.
Shelf life 18 months.
AWRK5000112 Provides up to 12 months operation.

Sodium reagent kit DIPA 6 x 1 liter bottles.
Shelf life 1 year.
AW501 036 ASO550 reference electrode for reservoir-fed
AWRK5000113 systems
Sodium 4 x 0.5 liter bottles.
regeneration kit
AWRK5000114
Sodium 6 x 1 liter bottles 100 ppb.
standards kit 6 x 1 liter bottles 1000 ppb.
Navigator 500
Part No. Description Part No. Description
1048880 Sodium electrode cable assembly AW501 053 Solenoid valve – Multi-stream Cal / Stream
switch
Port configuration W.R.T
electrical connector
N/O
T
IN/OU
AW501 037 Reservoir-fed electrode upgrade kit N / C
AW501 077 Solenoid valve – Single-stream, stream

diversion
Port configuration W.R.T
electrical connector
N/C
T
IN/OU
N/O
AW501 054 Funnel – drain
AW501 040 Bottle carrier assembly, including handles

(accessory)
AW501 055 Multi-stream manifold assembly
AW501 050 Sodium wet-section PCB
AW501 056 Flowcell assembly
AW501 051 PCB housing seals
AW501 052 Terminal cover, O-ring and screws
Navigator 500
AW501 057 Sodium electrode sleeve and O-ring AW501 062 Pressure switch assembly (2 in.set point)
including O-ring and fasteners
LOW
AW501 058 Pt1000 assembly (sodium) plus O-ring

AW501 063 Solenoid valve mounting plate, calibration and
stream switching
AW501 059 Pt1000 sleeve and O-ring
AW501 060 O-ring pack (4off) – Pt1000 and electrodes
AW501 064 Sample adaptor kit – non-flowmeter
AW501 061 Constant head assembly including connectors

and O-ring
AW501 065 Entrainment piece assembly
Navigator 500
AW501 066 Entrainment tube and connecting tubing AW501 070 Calibration solution bottle kit assembly –
includes hazard labels: Calibration Solution 1
and Calibration Solution 2
AW501 067 Entrainment tube centralizing collar
AW501 071 Reagent solution bottle kit assembly –

AW501 068 Flowmeter – sodium includes hazard labels for Ammonia solution
and separate hazard label for Di-
isopropylamine (DIPA) solution
AW501 069 Flowmeter adaptor kit
AW501 072 Regeneration solution bottle kit assembly –

includes hazard label
AW501 075 Tubing kit (includes tubing supplied in AW501

076) – required for 12-monthly maintenance,
(see Section 8.2.3, page 61)
AW501 076 Calibration and reagent solution tubing only kit

– required for 12-monthly maintenance (see
Section 8.2.3, page 61)
Navigator 500
Part No. Description
AW501 080 Cable assembly – single-stream sodium

solenoid valve
AW501 081 Cable assembly – multi-stream sodium

solenoid valve
AW501 082 Cable assembly – calibration and reagent

solenoid valve
AW501 085 Cable assembly – pressure switch
AW501 086 Cable assembly – flowmeter single-stream
AW501 087 Cable assembly – flowmeter multi-stream
Modbus cable assembly:

AW501 090 1.5 m (4.9 ft.)
AW501 091 5 m (16.4 ft.)
AW502 092 10 m (32.8 ft.)
AW502 093 20 m (65.6 ft.)
Navigator 500
D.3 Navigator 540 transmitter

AW500 050 AWT processor board spares kit AW500 054 AWT SD media PCB spares kit
AW500 055 AWT USB media PCB spares kit
AW500 051 AWT main board spares kit
AW500 056 Door assembly spares kit
AW500 052 AWT sensor input PCB (Digital RS485)
AW500 058 AWT Profibus DPV1 PCB
AW500 053 AWT analogue output PCB

(2 current outputs + relays)
SK1
AW500 060 AWT panel-mount kit SK2
Acknowledgements
Microsoft, Windows and Excel are registered trademarks of
Microsoft Corporation in the United States and/or other
countries.
Modbus is a registered trademark of the Modbus-IDA

organization.
Sales Service Software

—
ABB Limited
Measurement & Analytics
Oldends Lane, Stonehouse
Gloucestershire,
GL10 3TA
UK
Tel: +44 (0)1453 826661
Fax: +44 (0)1453 829671
Email: [email protected]
ABB Inc.
Measurement & Analytics
125 E County Line Road
Warminster, PA 18974
USA
Tel: +1 215 674 6000
Fax: +1 215 674 7183
abb.com/measurement
—
OI/ASO550-EN Rev. G 03.2019
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.
3KXA835550R4201

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Measurement made easy

The analyzer comprises a Navigator 540 transmitter

This Operating Instruction provides installation,

or by scanning this code:

Search for or click on

2 Overview .......................................................................... 6 6 Operation overview – transmitter ................................. 29

8 Maintenance ..................................................................59 Appendix A – Troubleshooting ......................................... 72

10 Specification – transmitter ............................................70

11 Specification – wet-section ..........................................71

1 Health & Safety

Warning. Installation, operation, maintenance and servicing must be performed:

1.2 Potential safety hazards

1.2.3 Navigator 540 transmitter – electrical

1.3 Safety standards

1.4 Safety conventions

Direct current supply only.

This symbol indicates the need for protective eye wear.

This symbol indicates the need for protective hand wear.

1.5.2 Navigator 540 transmitter

Functional earth (ground) terminal.

Alternating current supply only.

Recycle separately from general waste under the WEEE directive

1.6 Product recycling and disposal (Europe only)

1.6.1 End-of-life battery disposal

1.7 Restriction of Hazardous Substances (RoHS)

Reagent tube bottle to entrainment T-piece Regeneration solution bottle (optional)

Remote reference reservoir (optional) Calibration solution 1tubing to

Entrainment 'T' piece

Pt1000 temperature compensator

Stud terminal (ground) Sample stream inlets (front entry)

Sample stream drain tubing

2.2 Navigator 540 transmitter

Gland / cable entries

Fig. 2.2 Navigator 540 transmitter – main components

Maximum cable distance – transmitter to

Minimum distance between top of wet

Avoid vibration IP54

Fig. 3.1 Wet-section location

3.1.3 Mounting the wet-section

37 (1.45) 185 (7.28)

Fig. 3.2 Sodium wet-section dimensions

Referring to Fig. 3.3:

Note. It is not possible to adjust fixing A once the

Fig. 3.3 Mounting the wet-section

3.1.4 Connecting the external sample lines

To make external sample inlet connections:

Fig. 3.4 Connecting the external sample lines

3.1.5 Connecting the reagent / calibration / regeneration tubing

Fig. 3.5 Reagent, calibration and (optional) regeneration tubing connections

3.2 Installing the transmitter

3.2.2 Transmitter location 35 92

Warning. The transmitter is not fitted with a switch – an

Cable gland kit

Panel clamp anchor screw

Fig. 3.6 Transmitter location * To DIN43700

Fig. 3.7 Transmitter panel-mount option

3.2.4 Pipe mounting 3.2.5 Wall mounting

Dimensions in mm (in.) Dimensions in mm (in.)