User Guide IM/NAV6S/MS–EN Rev.

D
The Company
We are an established world force in the design and manufacture of measurement products for industrial process control, flow
Navigator 600 Silica measurement, gas and liquid analysis and environmental applications.

Multi-stream As a part of ABB, a world leader in process automation technology, we offer customers application expertise, service and support
worldwide.
We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and support.
The quality, accuracy and performance of the Company’s products result from over 100 years experience, combined with a
continuous program of innovative design and development to incorporate the latest technology.

Introduction
The Navigator 600 Silica is an advanced colorimetric
analyzer used to measure the level of silica in the steam
water cycle in power plants. This multi-stream version can
sample up to six independent streams sequentially.
This manual applies only to Navigator 600 Silica model
numbers AW641/xxxxx9xx
Configuration Level

Common Configuration

Measurement

Logging Level*

Alarm Relays Current Outputs

Logging

Not enabled from:

Communications Audit Log
Alarm Event Log

*This level cannot be accessed

from 'Configuration /Logging'
Navigator 600 Silica
Multi-stream Contents

Contents
1 Safety ............................................................................... 3 5 Configuration ................................................................ 25
1.1 Health & Safety ........................................................ 3 5.1 Front Panel Controls .............................................. 25
1.2 Electrical Safety – CEI / IEC 61010-1:2001-2 ........... 3 5.2 Navigation and Editing ........................................... 25
1.3 Symbols – CEI / IEC 61010-1:2001-2 ...................... 4 5.2.1 Text Editing ................................................ 25
1.4 Product Recycling Information ................................. 5 5.2.2 Numeric Editing .......................................... 25
1.5 Product Disposal ...................................................... 5 5.2.3 Other Methods of Editing ........................... 26
1.6 Restriction of Hazardous Substances (RoHS) ........... 5 5.2.4 Menus ........................................................ 26
1.7 Chemical Reagents .................................................. 5 5.3 Common ............................................................... 28
1.8 Safety Precautions ................................................... 5 5.3.1 Setup ......................................................... 28
1.9 Safety Conventions .................................................. 6 5.3.2 Screen ....................................................... 28
1.10 Safety Recommendations ........................................ 6 5.3.3 Time ........................................................... 29
1.11 Service and Repairs ................................................. 6 5.3.4 Security ...................................................... 30
1.12 Potential Safety Hazards .......................................... 6 5.3.5 User ........................................................... 32
5.3.6 Messages .................................................. 33
2 Overview .......................................................................... 7 5.4 Measurement ....................................................... 34
5.4.1 Setup ......................................................... 34
5.4.2 Streams ..................................................... 35
3 Principle of Operation ..................................................... 8
5.4.3 Diagnostics ................................................ 35
3.1 Chemical Principle .................................................... 8 5.5 Alarm Relays ......................................................... 36
3.2 Liquid Handling ...................................................... 10 5.6 Current Outputs ..................................................... 38
3.3 Multi-Stream Operation .......................................... 12 5.7 Logging ................................................................. 39
3.4 Single Stream Operation for Maintenance .............. 14 5.7.1 Recording .................................................. 39
3.5 Out of Sample ........................................................ 14 5.7.2 Chart .......................................................... 39
5.7.3 Archive ....................................................... 40
4 Installation ..................................................................... 15 5.8 Communications ................................................... 41
4.1 Accessories ........................................................... 15 5.8.1 Ethernet ..................................................... 41
4.2 Sampling Requirements ......................................... 16 5.8.2 email 1 and email 2 .................................... 42
4.3 Location ................................................................. 16
4.4 Reagent Bottle Location ......................................... 17 6 Start-up ......................................................................... 43
4.4.1 Behind Mounting Plate or Wall .................... 17 6.1 Commissioning the Analyzer .................................. 43
4.4.2 To Side of Analyzer ..................................... 17 6.1.1 Start-up and Configuration ......................... 43
4.4.3 Below Analyzer ........................................... 17 6.2 Performing a Baseline Calibration .......................... 44
4.5 Mounting ................................................................ 18
4.5.1 Mounting Dimensions ................................. 18
7 Calibration & Maintenance ........................................... 45
4.5.2 Mounting the Analyzer ................................ 19
4.5.3 Mounting the Reagent Shelf (Optional) ........ 19 7.1 Zero Calibration ..................................................... 46
4.6 Electrical Connections ............................................ 20 7.2 Secondary Calibration ........................................... 47
4.6.1 Connections Overview ................................ 21 7.3 Cleaning ................................................................ 47
4.6.2 Accessing and Making Connections ........... 22 7.4 Setup Calibration / Clean ....................................... 48
4.6.3 Ethernet Connections ................................. 23 7.5 Calibration ............................................................. 49
4.6.4 Alarm Relay Contact Protection and
Interference Suppression ............................ 23 8 Maintenance ................................................................. 50
4.7 Preparing the Analytical Section ............................. 24 8.1 Scheduled Maintenance ........................................ 50
4.7.1 Connecting Sample Inlet and Drain Line(s) .. 24 8.1.1 Chemical Solutions ..................................... 50
4.7.2 Connecting the Contaminated Drain Tube .. 24 8.1.2 Solution Replacement ................................ 51
8.1.3 Annual Service ........................................... 51
8.2 Periodic Maintenance ............................................ 53
8.2.1 Sample Filter Replacement ......................... 53
8.2.2 Reagent Tube Filter Replacement ............... 53
8.3 DC Fuse Replacement ........................................... 54
8.4 Manual Test Settings ............................................. 54
8.5 Start / Stop Pumps ................................................ 54

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9 Logging ..........................................................................55 Appendix D – Online Help ................................................. 80

9.1 SD Cards ...............................................................56
9.2 Reset Archiving ......................................................57 Appendix E – Web Server ................................................. 81
9.3 File Viewer ..............................................................57 E.1 Stream Values ........................................................ 82
9.4 Archive File Types ...................................................58 E.2 Reagent & Solution Levels ..................................... 82
9.5 Data Files ...............................................................58 E.3 Measurement Status .............................................. 82
9.5.1 Data Filenames ...........................................58 E.4 Valve & Pump Status ............................................. 82
9.5.2 Log Files .....................................................59 E.5 Statistics ................................................................ 82
9.5.3 Daylight Saving ...........................................59 E.6 System Information ................................................ 82
9.5.4 Filename Examples .....................................59 E.7 Logging Status ...................................................... 82
E.8 Operator Messages .............................................. 83
10 Chart Functions .............................................................60 E.9 Configuration ......................................................... 83
10.1 Historical Review ....................................................60 E.10 FTP Access ........................................................... 83
10.2 Operator Messages ................................................60 E.11 FTP Access via Internet Explorer ............................ 84
10.3 Chart Annotation ....................................................60 E.12 FTP Access via DataManager ................................ 84
10.4 Screen Interval .......................................................60 E.13 File Transfer Program ............................................. 84
10.5 Scales ....................................................................61
10.6 Trace Select ...........................................................61 Appendix F – Updating the Software ............................... 85

11 Alarm Acknowledge ......................................................61 Appendix G – Analyzing a Grab Sample .......................... 86

12 Diagnostic Information ..................................................62 Appendix H – Spare Parts ................................................ 87

12.1 Reagent and Solution Levels ..................................62
12.2 System Information ................................................62
12.3 Measurement Status ..............................................62
12.4 Valves and Pumps Status .......................................63
12.5 Statistics ................................................................63

13 Specification ..................................................................64

Appendix A – Solutions .....................................................66

A.1 Reagent Solutions ..................................................66
A.2 Secondary Calibration Solutions .............................66
A.3 Cleaning Solution ...................................................67
A.3.1 Regular Cleaning Solution (for Automatic
Cleaning Operation) ....................................67
A.3.2 Extra Strength Cleaning Solution (for
Troubleshooting and More Intense
Wet Section Cleaning) .................................67
A.3.3 Safety Labels ..............................................67

Appendix B – Diagnostics and Alarms .............................68

B.1 Analyzer Diagnostic Information ..............................68
B.2 Audit Log and Alarm Event Log ..............................74
B.2.1 Audit Log – Icons ........................................74
B.2.2 Alarm Event Log – Icons .............................74

Appendix C – Troubleshooting .........................................75

C.1 Analyzer Malfunction ..............................................75
C.2 Single-Stream Mode for Maintenance .....................75
C.3 Calibration Errors and Noisy or Incorrect Readings .75
C.3.1 Air in System ...............................................76
C.3.2 Optical System Errors .................................77
C.3.3 Chemistry and Color Generation Errors .......78
C.3.4 Zero and Secondary Calibration Valve
Malfunction .................................................79

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Navigator 600 Silica
Multi-stream 1 Safety

1 Safety
Information in this manual is intended only to assist our customers in the efficient operation of our equipment. Use of this manual for
any other purpose is specifically prohibited and its contents are not to be reproduced in full or part without prior approval of the
Technical Publications Department.

1.1 Health & Safety

Health and Safety

To ensure that our products are safe and without risk to health, the following points must be noted:
 The relevant sections of these instructions must be read carefully before proceeding.
 Warning labels on containers and packages must be observed.
 Installation, operation, maintenance and servicing must only be carried out by suitably trained personnel and in accordance
with the information given.
 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. Normal safe
handling procedures must be used.
 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 Electrical Safety – CEI / IEC 61010-1:2001-2

This equipment complies with the requirements of CEI / IEC 61010-1:2001-2 'Safety Requirements for Electrical Equipment for
Measurement, Control and Laboratory Use' and complies with US NEC 500, NIST and OSHA.
If the equipment is used in a manner NOT specified by the Company, the protection provided by the equipment may be impaired.

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Navigator 600 Silica
Multi-stream 1 Safety

1.3 Symbols – CEI / IEC 61010-1:2001-2

One or more of the following symbols may appear on the equipment labelling:

This symbol indicates the presence of devices

Protective earth (ground) terminal. sensitive to electrostatic discharge and indicates
that care must be taken to prevent damage to
them.
Functional earth (ground) terminal.
This symbol identifies a risk of chemical harm and
indicates that only individuals qualified and trained
Direct current supply only. to work with chemicals should handle chemicals or
perform maintenance on chemical delivery
Alternating current supply only. systems associated with the equipment.

This symbol indicates the need for protective eye

Both direct and alternating current supply. wear.

The equipment is protected through double This symbol indicates the need for protective hand
insulation. wear.

This symbol, when noted on a product, indicates a Electrical equipment marked with this symbol may
potential hazard that could cause serious personal not be disposed of in European public disposal
injury and / or death. systems. In conformity with European local and
national regulations, European electrical equipment
The user should reference this instruction manual
users must now return old or end-of-life equipment
for operation and / or safety information.
to the manufacturer for disposal at no charge to
This symbol, when noted on a product enclosure the user.
or barrier, indicates that a risk of electrical shock
Products marked with this symbol indicates that
and / or electrocution exists and indicates that only
the product contains toxic or hazardous
individuals qualified to work with hazardous
substances or elements. The number inside the
voltages should open the enclosure or remove the
symbol indicates the environmental protection use
barrier.
period in years.
This symbol indicates that the marked item can be
hot and should not be touched without care.

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Multi-stream 1 Safety

1.4 Product Recycling Information

Electrical equipment marked with this symbol may not be disposed of in European public disposal systems after 12
August 2005. In conformity with 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.

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.

1.5 Product Disposal

Note. The following only applies to European customers.

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. The European Waste Electrical and Electronic Equipment (WEEE) Directive (2002/96/EC)
that came into force on August 13 2005 aims to reduce the waste arising from electrical and electronic equipment; and
improve the environmental performance of all those involved in the life cycle of electrical and electronic equipment.
In conformity with European local and national regulations (EU Directive 2002/96/EC stated above), electrical equipment
marked with the above symbol may not be disposed of in European public disposal systems after 12 August 2005.

1.6 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 instruments 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.

1.7 Chemical Reagents

Warning. To familiarize yourself with handling precautions, dangers and emergency procedures, always review the Material
Safety Data Sheets prior to handling containers, reservoirs, and delivery systems that contain chemical reagents and standards.
Protective eye wear and protective hand wear. is always recommended when contact with chemicals is possible.

1.8 Safety Precautions

Please read the entire manual before unpacking, setting up, or operating this instrument.
Pay particular attention to all warning and caution statements. Failure to do so could result in serious injury to the operator or damage
to the equipment.
To ensure the protection provided by this equipment is not impaired, do not use or install this equipment in any manner other than
that specified in this manual.

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Navigator 600 Silica
Multi-stream 1 Safety

1.9 Safety Conventions

Warning. In this manual, a warning is used to indicate a condition that, if not met, could cause serious personal injury and / or
death. Do not move beyond a warning until all conditions have been met.
If a warning sign appears on the instrument itself, refer to Precautionary Labels – UL Certification and Electrical Safety – CEI/IEC
61010-1:2001-2 for an explanation.

Caution. A caution is used to indicate a condition that, if not met, could cause minor or moderate personal injury and / or
damage to the equipment. Do not move beyond a caution until all conditions have been met.

Note. A note is used to indicate important information or instructions that must be considered before operating the equipment.

1.10 Safety Recommendations

For safe operation, it is imperative that these service instructions be read before use and that the safety recommendations mentioned
herein be scrupulously respected. If danger warnings are not heeded to, serious material or bodily injury could occur.

Warning. The installation of the instrument must be performed exclusively by personnel specialized and authorized to work on
electrical installations, and in accordance with relevant local regulations.

1.11 Service and Repairs

Other than the serviceable items listed in Appendix H, page 87, none of the instrument's components can be serviced by the user.
Only ABB personnel or ABB-approved representatives are authorized to attempt repairs to the system and only ABB-approved
components must be used. Any attempt at repairing the instrument in contravention of these principles could cause damage to the
instrument and injury to the person carrying out the repair. It renders the warranty null and void and could compromise the correct
working of the instrument and the electrical integrity or the CE compliance of the instrument.
If you have any problems with installation, starting, or using the instrument please contact the company that sold it to you. If this is not
possible, or if the results of this approach are not satisfactory, please contact the manufacturer's Customer Service.

1.12 Potential Safety Hazards

The following potential safety hazards are associated with operating the analyzer:
 Electrical (line voltage)
 Potentially hazardous chemicals

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Navigator 600 Silica
Multi-stream 2 Overview

2 Overview
The measurement of silica in a sample involves the addition of To maintain optimum measurement accuracy, the analyzer
various chemical reagent solutions* to the sample, in a specific performs a zero and secondary calibration automatically, at
order, under constant temperature conditions. The result is a predetermined intervals, using solenoid valves.
chemical complex, in solution, that has a characteristic color.
Data is stored in the analyzer's internal memory and can be
The absorbance of this colored complex is proportional to the
archived either to an SD Card or via an internet connection. The
concentration of the silica in the original sample, thus making it
SD card can also be used to upgrade the analyzer's software –
possible for the measurement to be made optically. During
see Appendix F, page 85.
operation, a signal generated from the sensing system is
converted by the analyzer into data and this information is *For information about reagent solutions, contact your local ABB
presented on the display. representative.

Analyzer main components are shown in Fig. 2.1. The hinged

lower door provides environmental protection for the liquid
handling section to ensure stabilized measurement conditions.

Cable Entries
(Both Sides
of the Case)
Hinged Door to Liquid
Handling Section
Display Electronics Section

Keypad

Peristaltic Pump

Reaction Block

Liquid Handling Section

*Date Label

Constant-head Unit

*A second (identical) Date Label is fixed to the underside of the Electronics Section

Fig. 2.1 Main Components

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Navigator 600 Silica
Multi-stream 3 Principle of Operation

3 Principle of Operation
3.1 Chemical Principle
The chemical method used by the analyzer is based on the 6. The reduction solution is added to reduce the yellow
reaction of ammonium molybdate with silicate species, in acidic molybdosilicic acid complex to the more
conditions, to form a yellow molybdosilicic acid complex. To optically-absorbent blue form. The solution enters the third
improve the sensitivity of the method the yellow complex is reaction coil that provides a 1 minute delay.
reduced to the blue form. The absorbance of the blue complex
7. The amount of blue color formed is directly proportional to
is measured spectroscopically in the optical system.
the concentration of silica in the sample. The fully
Referring to Fig. 7.3, the sequence of events in the analyzer is as developed solution passes to the measuring cuvette
follows: where the intensity of the color is measured.
1. Sample flows into a reaction coil that is maintained at a 8. During the zero calibration the analyzer generates a zero
temperature of 45 °C (113 °F). solution by diverting the sample to the point where the
second acid is added. The pH at this point is too low for
2. The first acid reagent is added to the sample to reduce the
any silica in the sample to react with the molybdate, so a
pH to a value between 1.4 and 1.8.
zero solution is produced (refer also to Section 7.1, page
3. Ammonium molybdate is added to the acidified sample. 46.
4. The first reaction coil provides a 2-minute delay where the During the zero calibration the system allows any silica
yellow molybdosilicic acid is developed. present in the first acid and molybdate solutions
5. The second acid reagent is then added to reduce the pH (Reagents 1 and 2) to form the yellow molybdosilicic acid
value further to between 0.8 and 1.0. This is the value complex. This is then converted to the blue form when it
required to stop the formation of the yellow complex. The reacts with the reduction solution.
solution enters the second delay coil that provides a
further 2 minutes for the reaction to take place.

Note. In applications where the sample contains

phosphate, the second acid reagent has a different
formulation to destroy any molybdophosphoric acid
complexes that would form an interfering blue
complex in the next stage of the reaction.

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Navigator 600 Silica
Multi-stream 3 Principle of Operation

Reacted sample to optical unit

Temperature controlled at 45 ° C (167F)

Production of blue
molybdosilicic acid complex

1 Minute
0.8 to 1.0 pH providing reducing conditions
to stop formation of yellow complex Reduction Solution

2 Minutes
1.4 to 1.8 pH providing conditions for the Second Acid
production of yellow ß-molybdosilicic acid
2 Minutes
Molybdate

First Acid
Sample
Auto-zero valve

Fig. 3.1 Chemical Schematic

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Navigator 600 Silica
Multi-stream 3 Principle of Operation

3.2 Liquid Handling

Referring to Fig. 3.2: The sample passes through the clean and secondary calibration
valves before entering a pre-heater coil that heats the sample to
The sample enters the analyzer via the constant head unit 1
encourage dissolved air in the sample to form bubbles. These
situated at the bottom of the unit. Multi-stream analyzers can
bubbles are removed by the primary debubbler 3 and pumped
have 2, 4 or 6 constant head units fitted, depending on the
to drain by the de-gassing channel on the peristaltic pump. This
version. Each constant head unit is fitted with an 'Out of
is necessary to reduce the effect of bubbles in the sample
Sample' switch that determines if sample is present. This is
causing variable reagent mixing, resulting in noisy readings.
used by the microprocessor to measure only streams with
sample present. If all streams are out of sample, the analyzer The sample then passes through the zero valve 4 and into the
instigates a Shutdown procedure (see Section 3.5, page 14). heated reaction coil 5 where it mixes with the reagents to form
Once a sample stream returns the analyzer re-starts a blue complex (described in detail in Section 3.1, page 8).
automatically.
The sample exits the reaction coil and passes into the
Each constant head unit is fitted with a solenoid valve. The secondary debubbler assembly 6. This dual-purpose
valves are used to select each stream to be sampled. assembly:
The sample is drawn up from the constant head unit by the removes any bubbles that may have originated from the
peristaltic pump 2 via a sample filter that protects the liquid reagents or by further degassing of the sample
handling section from blockages caused by particulates in the
and
sample.
diverts the sample flow away from the cuvette via a solenoid
Note. If particulates exceed 60 microns in size, it is valve during the optical measurement phase
essential to fit external filters to the sample lines prior to
entering the analyzer. Although the reaction of the sample is continuous, the sample
flow into the cuvette is stopped 2 minutes prior to the optical
measurement. This is achieved by diverting the sample to drain
just prior to cuvette. The 2 minute delay allows the solution in
the cuvette to settle so that an accurate absorbance reading
can be achieved.

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Navigator 600 Silica
Multi-stream 3 Principle of Operation

Secondary Debubbler
6

To Drain
Cuvette Valve

2 Peristaltic Pump

Cuvette

Reaction
4 Block
Auto-zero Valve
5
Primary To Drain
3
Debubbler

Secondary Pre-heater
Calibration Valve Assembly

Cleaning Valve

Constant Head Unit(s)

Sample
Filter
1

Sample(s)
Cleaning Calibration Reduction 2nd Acid Molybdate 1st Acid
Solution Solution

Fig. 3.2 Flow Schematic

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Navigator 600 Silica
Multi-stream 3 Principle of Operation

3.3 Multi-Stream Operation

Between 2 and 6 sample streams can be fitted to the analyzer The analyzer uses the value of the maximum measurement
depending on the version. The sample streams are connected range set in Configuration to determine whether to utilize the
to constant head units and a solenoid valve connected to each upscale or downscale sampling time. When switching from one
constant head unit selects the stream to be sampled by the stream to the next, if the maximum range value:
analyzer.
decreases – the downscale time is used
The analyzer samples the streams in a sequence that is defined
increases – the upscale time is used
in the Configuration menu (see Section 5, page 25). The
sampling time is set to a minimum of 12 minutes for upscale does not change – the upscale time is used.
changes and 14 minutes for downscale changes. Sampling
times are user-configurable up to 60 minutes and may need to The analyzer dead time (the time between the stream valve
be increased from the default values of 12 and 14 minutes if energizing and the corresponding response on the analyzer
carry-over effects become significant. The upscale time should display) is approximately 12 minutes. This dead time is utilized in
be equal to, or less than, the downscale time. Table 3.1 lists the analyzer to minimize the stream sampling time (refer to
recommended minimum downscale sampling times for some Fig. 3.3, page 13). The stream valve (stream 1) is on for the
typical stream values. The minimum times recommended should allotted sampling time, it then switches off and the next stream
ensure that accurate silica readings are returned in the fastest valve in the sequence switches on. The reading for stream 1 is
possible time. not taken for another 11 minutes; this enables a stable reading
of stream 1 to be taken in the shortest duration.
High Concentration Low Concentration Minimum Downscale
Soon after the reading for stream 1 has been updated, the next
Value Value Time
stream in the sequence begins to enter the cuvette and the
50 ppb 5 ppb 14 minutes signal starts to respond.
200 ppb 5 ppb 18 minutes The reading for each stream is held until it is sampled and
updated again. The reading is also held if there is a 'Loss of
500 ppb 5 ppb 26 minutes Sample' on that stream or the stream is de-selected. If all but
500 ppb 50 ppb 20 minutes one stream is out of sample, the duration between reading
updates is the upscale sampling time.
2000 ppb 50 ppb 26 minutes
If a stream is unavailable during the sampling period the analyzer
Table 3.1 Suggested Downscale Sampling Times selects the next available stream in the sequence.
to Reduce Effects of Carry-Over
The stream sequence is normally set to sample each stream in
turn – for example, on a 4-stream analyzer the sequence would
be set to 1, 2, 3, 4. However, greater priority could be given to a
particular stream, for example, stream 1, by programming the
sequence 1, 2, 1, 3, 1, 4 or 1, 1, 2, 3, 4 and so on.
To ensure the most accurate zero, connect the lowest expected
silica stream to stream 1.

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Multi-stream 3 Principle of Operation

Yellow Sampling Blue Update

Symbol Displayed Symbol Displayed
Reading Taken for Reading Taken for Reading Taken for
Stream 1 Stream 2 Stream 3

Stream 1 Stream 2 Stream 3 Stream 4

Solenoid Valve Open Solenoid Valve Open Solenoid Valve Open Solenoid Valve Open
Dead Time 11.5 minutes. Dead Time 11.5 minutes.

Sampling Interval Update Time

Nominal 12 minutes. 10 minutes.
Toggles between time left to end of update
and time of last update

Sampling period and amount of time left

(the period the stream solenoid is
energized)

Update period – time left before

the stream value is updated

Fig. 3.3 Multi-Stream Timing

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Multi-stream 3 Principle of Operation

3.4 Single Stream Operation for Maintenance 3.5 Out of Sample

It may be necessary to switch the analyzer to single stream If the analyzer detects that a sample is lost (via the out of sample
mode during commissioning or to carry out maintenance. switch) during its sampling period, it continues to sample for 10
seconds and then switches to the next enabled stream in the
Single stream mode is initiated by enabling one stream only. This
sequence that has sample present.
stops the multi-stream sequence and results in reading updates
every 3 minutes – 1 minute sample flowing in the cuvette, 2 If an enabled stream in the sequence is not present the analyzer
minutes sample stopped in the cuvette. The analyzer is not skips that stream and goes to the next enabled stream in the
designed to run in this mode continuously, but it can be used to sequence. If all but one stream is out of sample, the duration
check the basic performance on the analyzer without having to between reading updates is the upscale sampling time.
wait for the normal stream update.
If all streams are out of sample the analyzer shuts down
Selecting more than one stream puts the analyzer back into automatically to prevent air being drawn into the analyzer and to
multi-stream operation. conserve reagents.
The automatic shutdown procedure is:
1. The reagent pump stops.
2. Secondary calibration solution is pumped through the
system to purge the reaction coil of reagents and
developed solution.
3. The sample pump, reaction heater and pre-heater are
switched off.
4. The analyzer waits in standby mode until a sample is
restored.
5. When a sample returns and the analyzer has been out of
all samples for less than 24 hours a purge sequence is
started.
If the analyzer has been out of all samples for more than
24 hours a purge and clean sequence is started.

If all enabled streams are out of sample, but there are disabled
streams with sample present, the analyzer continues to run on
the available disabled stream. The diagnostic message 'No valid
streams available' is displayed in the diagnostic window. Stream
values are not updated, but the analyzer continues to run and
perform scheduled calibrations and cleans.
As soon as an enabled stream has sample present the
multistream sequence initiates and the readings update
accordingly.

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Multi-stream 4 Installation

4 Installation
4.1 Accessories
The following accessories are supplied with the analyzer:
4 x 2.5 l reagent bottle and cap
1 x 500 ml cleaning solution bottle and cap
1 x 500 ml standard solution bottle and cap
1 x DataManager software CD

Cable Gland Kit comprising:

10 x two-wire cable glands for relays or Profibus
1 x one-wire cable gland for power
11 x nuts for above glands
11 x O-rings for above glands
1 x large cable gland, washer and nut for Ethernet

Annual Spares Kit including:

4 x capstans
2 x capstan covers
1 x set of pump tubes
14 x filter discs

Optional accessories that may have been ordered with

the analyzer include:
2 x reagent shelves
1 x Profibus card, installed
1 x Profibus manual

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Navigator 600 Silica
Multi-stream 4 Installation

4.2 Sampling Requirements

The sampling point must be as near as possible to the analyzer and must provide a thoroughly mixed, representative sample.
The sample must conform to the following conditions:
 Sample must contain less than 10 ppm suspended solids with a particle size no greater than 60 µm.
(If particle sizes exceed 60 µm, use a 60 µm filter.)
 Sample temperature must be within the range 5 to 55 °C (41 to 131 °F).
 Sample flow rates must be within the range 20 to 500 ml/min.
 Sample must be at atmospheric pressure.

4.3 Location
For general location requirements refer to Fig. 4.1. Install indoors in a clean, dry, well ventilated and vibration-free location giving easy
access and where short sample lines can be used. Avoid rooms containing corrosive gases or vapors – for example, chlorination
equipment or chlorine gas cylinders.
Select a location away from strong electrical and magnetic fields. If this is not possible, particularly in applications where mobile
communications equipment is expected to be used, screened cables within flexible, earthed metal conduit must be used.
It is also advisable to ensure drains are adjacent and near ground level, so that the analyzer waste outlet can be as short as possible,
together with maximum fall.
Mount reagent solutions less than 1 m (3.28 ft) from the bottom of the analyzer housing – see Fig. 4.2, page 17.
Ensure that the power supply and power isolation switch are adjacent to the analyzer.

Near to Above Ambient

Sample Sea Level < 2000 m Temperature
(< 6561 ft.) 45 °C
(113 °F)
Filtered Max.
5 °C
Sample
(41 °F)
Min.
Eye-level
Location
Avoid
Vibration Humidity
0 to 95%

Fig. 4.1 Location

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4.4 Reagent Bottle Location

4.4.1 Behind Mounting Plate or Wall 4.4.2 To Side of Analyzer
To prevent reagent flow due to gravity during maintenance,
Caution. Do not place reagent bottles on the floor. ensure top of reagent bottles are below the level of the pumps.
Ensure reagent tubes reach the bottom of all 4 reagent bottles.

Dimensions in m (ft.) Dimensions in m (ft.)

Ensure top of reagent bottles

are below level of pumps

Reagent tube length 1.3 (4.26)

Maximum 1 (3.28)
Reagent tube length 1.3 (4.26)
Maximum 1 (3.28)

Fig. 4.3 Reagent Bottles Mounted to the Side of the Analyzer

4.4.3 Below Analyzer

Mount the reagent bottles below the front of the analyzer and
install a protective cover (not supplied) over the reagent bottles.

Fig. 4.2 Reagent Bottles Mounted Behind Dimensions in m (ft.)

the Mounting Plate or Wall

Reagent tube length 1.3 (4.26)

Protective Cover
(not supplied)
Maximum 1 (3.28)

Fig. 4.4 Reagent Bottles Mounted Directly Below the Analyzer

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4.5 Mounting
4.5.1 Mounting Dimensions

Dimensions in mm (in.)
314 (12.36) 182 (7.16)
271 (10.67)

638 (25.12)
770 (30.31)
Maximum 1000 (39.4)

Maximum 1000 (39.4)

122 (4.80)
289 (11.34)
184 (7.25)

280 (11.02) 150 (5.90)

560 (22.05) 300 (11.81)

Reagent bottles mounted on optional brackets (two bottles per bracket) Example – two brackets mounted side-by-side
– see Sections 4.4.1, 4.4.2 and 4.4.3, page 17 for reagent bottle mounting options with end plates attached to wall

Fig. 4.5 Mounting Dimensions

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4.5.2 Mounting the Analyzer 4.5.3 Mounting the Reagent Shelf (Optional)

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

165 114 165
(6.59) (4.48) (6.59)

82
(3.23)

525 75 76 75
(20.7) (2.95) (3.00) (2.95)

81
(3.18)

Fig. 4.7 Reagent Mounting Shelf (option)

If used, mount the reagent shelf(ves) no more than 1 m (3.3 ft.)

from the analyzer’s bottom plate – see Fig. 4.5, page 18. Each
200 shelf can be attached through the back plate or either of the
(7.8) side plates. If two shelves are attached through their side plates,
ensure they are arranged with the back plates facing each other.
Referring to Fig. 4.7:
Fig. 4.6 Mounting the Analyzer
1. Mark the wall using the dimensions shown or, with the
shelf supported carefully against the wall, mark through
Note. Clearance – the enclosure doors can open 180°. If the mounting holes.
mounting in a confined area, allow sufficient clearance for 2. For each shelf, drill and plug holes suitable for M8 or
cables on the door hinge side (min. 270 mm, 10.6 in.) and 5
/16 in. fixings.
100 mm (3.93 in.) on door opening side.
3. Hang the shelf onto the screws and tighten the fixings to
secure the shelf firmly against the wall.
Referring to Fig. 4.6:
1. Mark the wall using the dimensions shown or, with the
analyzer supported carefully against the wall, mark
through the mounting holes.
2. Drill and plug 3 holes A and B, 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 analyzer onto fixing A, ensuring the analyzer is
retained firmly against the wall.

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

analyzer is placed over it. If necessary, remove the
analyzer and adjust the fixing.

5. Secure the analyzer to the wall using 2 fixings B.

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4.6 Electrical Connections

Warning.
 The analyzer is not fitted with a switch therefore 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 analyzer within easy reach of
the operator and must be marked clearly as the disconnection device for the analyzer.
 Remove all power from supply, relay and 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 0.8 to 2.5 mm2 (18 to 14 AWG).
 Ensure the correct fuses are fitted – Fig. 4.8, page 21, for fuse details.
 Use screened cable for signal inputs and relay connections.
 Replacement of the internal battery (type Varta CR2025 3V lithium cell) must be carried out by an approved technician only.
 The analyzer 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.
 If the analyzer is used in a manner not specified by the Company, the protection provided by the equipment may be
impaired.
 All equipment connected to the analyzer's terminals must comply with local safety standards (IEC 60950, EN61010-1).
 Route signal leads and power cables separately, preferably in an earthed (grounded) flexible metal conduit.
 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 (mains input and relay contact outputs), use only suitably rated field wiring insulated copper
conductors rated min. 300 V, 14 AWG, 90C. Route wires through suitably rated flexible conduits and fittings.

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4.6.1 Connections Overview

Note. Field wiring terminal screws must be tightened to a torque of 0.6 to 0.8 Nm (5 to 7 lbf.in).

Socket for
Optional Digital
Communications

NO NO Out of Service

TB2
Hold/Maintenance C
C Relay
Relay NC
NC

Ethernet RJ45
Connector NO NO
TB3 Calibration in
Calibration Failed C
C Progress Relay
Relay NC
O/P 6 NC

O/P 5 NO NO
C Alarm 1 Relay
TB4

C
Alarm 2 Relay NC
O/P 4 NC
TB7
Current Outputs
O/P 3 NO
NO Alarm 3 Relay
TB5

C
Alarm 4 Relay C
O/P 2 NC
NC

O/P 1
NO NO
Alarm 5 Relay
TB6

C C
Alarm 6 Relay
NC NC
TB8
Optional Digital AC Fuse 1 A Type T or **DC Fuse 12.5 A Type T
Communications
L +
N –
Use fuse rated:
E TB1
E
AC Supply 1 A (max.), Type T, 250 V
DC Supply* 12.5 A 125 V DC Type T 100 V to 240 V AC ±10 % 18 to 36 V DC
Manufacturer* SCHURTER, (90 V min. to 264 V max.) **see Fig. 8.4, page 54, for
Model SPT 5 x 20 Series 50 / 60 Hz DC fuse replacement details

Fig. 4.8 Connections Overview

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4.6.2 Accessing and Making Connections

Note.
 Cable entry holes are located on both sides of the enclosure.
 Application board connection labels for the terminal blocks are identified in Fig. 4.8, page 21.

Warning. Remove all power from supply, relay and any powered control circuits and high common mode voltages before
accessing or making any connections.

D
E

J I

G F H
B C

Fig. 4.9 Accessing and Making Electrical Connections

Referring to Fig. 4.9:

1. Turn door retaining screws A 1/4 turn counter-clockwise 7. Remove each connection plug J and, using a small
and open the electronics section door. flat-bladed screwdriver, make connections to the plug.
Ensure wires are connected to the correct terminals – see
2. Using a cross-head screwdriver, remove 4 screws B and
Fig. 4.8, page 21.
remove transparent cover plate C.
8. Reconnect the terminal block plugs to the appropriate
3. For each cable entry required, slide retaining clip D off
sockets on the application board.
blanking plug E and remove the plug.
9. Tighten gland nut H for each connection made.
4. Fit cable gland F and secure using nut G.
10. If required, fit the Ethernet cable – see Section 4.6.3,
5. Remove gland nut H and feed cable I through it.
page 23.
6. Feed the cable through cable gland F and into the
11. Replace transparent cover plate C and secure with 4
electronics section enclosure.
screws B.

Note. Cable glands are supplied with single- and 12. Close the electronics section door and turn door retaining
twin-holed bushes. Use the single-holed bush for the screws A 1/4 turn clockwise to secure.
mains power cable.

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4.6.3 Ethernet Connections 4.6.4 Alarm Relay Contact Protection and Interference
Suppression
Warning. Remove all power from supply, relay and any
powered control circuits and high common mode voltages NC C NO
Relay Contacts
before accessing or making any connections.

R C

E H G C Load
D External L N
AC Supply
A – AC Applications

I Relay Contacts
NC C NO
Diode
F

B A Load
External
DC Supply
+ –

B – DC Applications

Fig. 4.10 Ethernet Connections Fig. 4.11 Relay Contact Protection

The Ethernet gland is different from the other connections to If the relays are used to switch loads on or off, the relay contacts
accommodate an RJ45 plug: can become eroded due to arcing. Arcing also produces RFI
that can cause analyzer malfunctions and incorrect readings. To
1. Referring to Fig. 4.9: minimize the effects of RFI, arc suppression components are
a. Turn door retaining screws A 1/4 turn required; these are resistor / capacitor networks for AC
counter-clockwise and open the electronics section applications or diodes for DC applications. These components
door. are connected across the load.
b. Using a cross-head screwdriver, remove 4 screws B Maximum relay ratings are:
and remove transparent cover plate C.  250 V, 5 A AC, 1250 VA (non-inductive)
2. Referring to Fig. 4.10:  30 V, 5 A DC 150 W
a. Slide retaining clip A off blanking plug B and For AC applications, the value of the resistor / capacitor network
remove plug. depends on the load current and inductance that is switched.
b. Fit cable gland C and secure using nut D. Initially, fit a 100R / 0.022 µF RC suppressor unit. If the analyzer
malfunctions the value of the RC network is too low for
c. Remove gland nut E and feed cable F through it.
suppression and an alternative value must be used.
d. Fit split-bush G and split-washer H to cable F.
For DC applications fit a diode – see Fig. 4.11. For general
e. Feed the cable through cable gland C and into the applications use an alternative IN5406 type (600 V peak inverse
electronics section enclosure. voltage at 3 A).
f. Plug RJ45 connector I into the RJ45 socket on the
application board (see Fig. 4.8, page 21 for location Note. The minimum voltage must be >12 V and the
details) and tighten gland nut E. minimum current >100 mA for reliable switching.

3. Referring to Fig. 4.9:

a. Replace transparent cover plate C and secure with 4
screws B.
b. Close the electronics section door and turn door
retaining screws A 1/4 turn clockwise to secure.

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4.7 Preparing the Analytical Section

4.7.1 Connecting Sample Inlet and Drain Line(s) 4.7.2 Connecting the Contaminated Drain Tube

9 mm (1/3 in.)
PVC Tubing
A

A
6 mm (1/2 in.)
B
PVC Tubing
9 mm (1/3 in.)
PVC Tubing
Fig. 4.13 Connecting the Contaminated Drain Tube

A contaminated drain tube is supplied fitted to the analyzer. Cut

the tube to a suitable length at the free end to ensure it has no
kinks and is as short as possible. Keep the tube's cut end in free
space to eliminate the risk of air locks.
If an alternative contaminated drain tube is used, refer to
Fig. 4.13 and route contaminated drain tube A upwards
Fig. 4.12 Connecting the Sample Inlet and Drain Line(s)
through centre channel B and connect it to contaminated
drain collector C.
Note. To ensure an accurate zero calibration, connect the
sample with the lowest expected silica concentration to Note. Keep the contaminated drain tube as short as
Stream 1. possible and route it as vertically as possible to allow free
draining.

Referring to Fig. 4.12: If samples are to be recycled, use separate drains for
contaminated and sample outlets.
1. Connect sample inlet tube to constant-head unit sample
inlet connector A.
2. Connect drain tube to constant-head unit outlet connector
B.

3. Repeat steps 1 and 2 for remaining constant head units.

4. Refer to Section 6, page 43 to startup the analyzer.

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5 Configuration
5.1 Front Panel Controls 5.2 Navigation and Editing
Depending on the type of field to be edited, the software
provides a variety of methods for entering values.
5.2.1 Text Editing
If the field to be edited requires text, a keyboard is displayed:

Fig. 5.1 Front Panel Controls

a Menu Key – Displays or hides the context-sensitive

operator menu associated with each view. It also cancels
the menu without making a change or returns to the
previous menu level.
b Group Key – Toggles between the operator and log
screens.
Left Key – Scroll left.
c Up / Down Keys – Highlights menu items and
scrolls through previously recorded data.
d View Key – Toggles between the operator and graph
screens.
Right Key – Scroll right. To enter text, use the , , and keys to highlight the
e Enter Key – Selects the highlighted menu item. required character and press .
There are three set of characters, uppercase, lowercase and
symbols. To toggle between each, highlight the bottom,
right-hand button and press .
To finish, highlight 'OK' and press , or press to exit
without making any changes.
5.2.2 Numeric Editing
If the field to be edited requires a numeric value, a number-pad
is displayed:

To enter a number, use the , , and keys to highlight

the required number and press .
To finish, highlight 'OK' and press , or press to exit
without making any changes.

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5.2.3 Other Methods of Editing 5.2.4 Menus

There are several other methods of editing, for example: Press to open the menu and use the and keys to
select a menu item. Press to open the menu item:
Checkboxes

To toggle the selection, use the and keys to highlight the

required checkbox and press .
To finish, highlight 'OK' and press , or press to exit
without making any changes.
Slider Bars

To select a value, use the and keys to move the slider.

To finish, press or press to exit without making any
changes.
Tabs

To select a tab, use the and keys.

Note. The tab indicates that there are more tabs

available.

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Invalid Password
Entered
Displayed only if 'Security
system' parameter is set to
Displayed only if 'Security
'Basic' – see on-line help
system' parameter is set to
system
'Advanced' – see on-line
help system

Configuration Level
Protected
Valid Password
Entered

Edit the current configuration. Changes are not

implemented until saved on exit from Configuration

Open a configuration saved previously to internal or external storage

Configuration Level (up to 16 configurations can be stored in internal memory) – see Note 1
Unprotected

Cancel Toggle between internal / Accept

external storage selection

Cancel and return

Open a new configuration
to 'Operator' level
See Note 2 with the default settings –
see Note 1

Fig. 5.2 System Configuration

Note.
1. If 'New Configuration' or 'Open Configuration' is selected and the modified configuration file is saved, new data files for all
log files are created and any unarchived data is lost.
2. Existing security configuration parameters are retained when a configuration is opened from file or when a new
configuration is loaded (the security remains as currently configured). Check 'Load security configuration from file' to
overwrite the current configuration with data from the file to be loaded.
The option to load or retain the security configuration applies only to Advanced Security mode and is available only to the
System Administrator (User 1). If a new or existing configuration file is opened by a user other than the System
Administrator, existing security settings are retained.

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5.3 Common
There are nine Common Configuration screens:

5.3.1 Setup

Fields Description

Lists the available languages.

Language
A new language selection does not take effect until the configuration is saved.

The instrument (analyzer) tag text is displayed in the top-left corner of the operator views. Up to 20
Instrument Tag characters can be used.
The instrument (analyzer) tag is also displayed on the analyzer on configuration and audit log files.

5.3.2 Screen

Fields Description

Screen saver wait time The time delay for the screen-saver. The screen dims after the time set.

Toggles between 'Enabled' and 'Disabled'.

Note. An SD card must be fitted for screen capture.
Screen Capture
If enabled, press to capture the current log or chart screen to the VRD\BMP folder on the SD
card. A confirmation dialog box is displayed for each screen capture.

Brightness Adjusts the brightness of the screen.

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5.3.3 Time

Fields Description

Warning. Changing the time can result in the permanent loss of data. Once it is changed a warning
Date and Time
is displayed stating that recording is disabled until the configuration has been saved.

Enables automatic daylight saving time adjustment. Options are:

 Off. The 'Daylight Saving – Start' and 'Daylight Saving – End' fields are not available.
 Auto – USA. The start and end of the daylight saving period in the USA is calculated
automatically. The clock is incremented automatically by 1 hour at 2:00 am on the second
Sunday in March and decremented automatically by 1 hour at 2:00 am on the first Sunday in
Daylight Saving – Enable
November.
 Auto – Europe. The start and end of the daylight saving period in Central Europe is calculated
automatically. The clock is incremented automatically by 1 hour at 2:00 am on the last Sunday
in March and decremented automatically by 1 hour at 2:00 am on the last Sunday in October.
 Auto – Custom. The start and end date and time can be edited.

If 'Daylight Saving – Enable' is set to USA or Europe, the start date is displayed but cannot be edited.
Daylight Saving – Start
If 'Daylight Saving – Enable' is set to 'Custom' the date and time can be edited.

If 'Daylight Saving – Enable' is set to USA or Europe, the end date is displayed but cannot be edited.
Daylight Saving – End
If 'Daylight Saving – Enable' is set to 'Custom' the date and time can be edited.

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5.3.4 Security

'User 1' is the System Administrator and is the only user that has access to the 'Security type' parameter. User 1 details cannot be
changed by any other user.
There are two types of security:
 Basic
Enables up to four users to have access to the 'Configuration' menu. Each user has a password that can have up to four digits.
A separate password can be set to gain access to the 'Calibration & Maintenance' and 'Logging' menus. All four users use this
password.
 Advanced
Enables up to twelve users to have password-protected access to any of the 'Configuration', 'Calibration & Maintenance' or
'Logging' menus. Each user can be assigned a unique 20-digit (alphanumeric) case-sensitive password. A minimum password
length can be set.

Note. A separate password for access to the 'Calibration & Maintenance' and 'Logging' menus is not required.

User 1 can set permissions for each user to access the 'Calibration & Maintenance' and / or 'Logging' menus. Access to the
'Configuration' menu can also be set – see Section 5.3.5, page 32.
– Passwords are set by User 1. If permissions are set, users can subsequently change their own passwords.
– Password expiry dates can be set.
– Inactive user accounts can be disabled after a set time.
– Password failure limits can be set.
– A minimum password length can be set.

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Fields Description

A page opens with two fields:

 Security system – toggles between 'Basic' and 'Advanced'.
Security type
 Configuration security – toggles between 'Password protected' and 'Internal switch
protected'.

Set access to the 'Calibration & Maintenance' and 'Logging' menus.

If set to 'Off', no password is required.

Operator level security If set to 'On' and 'Security type' is set to 'Basic' an additional 'Operator level password' field is
displayed.
If set to 'On' and 'Security type' is set to 'Advanced', all users are required to enter their user
password to gain access to the 'Calibration & Maintenance' and 'Logging' menus.

Displayed only if 'Security system' is set to 'Basic' and 'Operator level security' is set to 'On'. All
Operator level password users are required to enter this password to gain access to the 'Calibration & Maintenance' and
'Logging' menus.

The following tabs are displayed only if 'Security System' is set to 'Advanced'.

Passwords are set initially by User 1 (System Administrator) but any user can subsequently change
their own password.
Reconfigure preset
When set to 'Yes' each user must change their password after it is used for the first time following
initial configuration.

Select the number of days that the password is valid for. When a password expires, the user is
Password expiry
prompted to provide a new password.

Inactive user disabling Select the number of days after which an inactive user's access privileges are de-activated.

Enter the number of consecutive incorrect password entries allowed by a user. If the number of
Password failure limit incorrect entries exceeds this limit, the user's access privileges are de-activated and can be
reinstated only by the System Administrator (User 1).

Min password length Sets the minimum length required for user's passwords.

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5.3.5 User

Fields Description

If 'Security system' is set to 'Basic' this tab lists the four users, User 1 to User 4. Selecting a user opens a new page with two
fields:
 Name – the user’s name, up to 20 characters.
 Password – each user can be assigned a unique 4-digit security code for Configuration level access.

If 'Security System' is set to 'Advanced' and User 1 (administrator) is logged on, the 'User' tab shows additional fields:

User 1 Name User 1 identification tag – up to 20 characters.

A page opens with two checkboxes to select whether User 1 has 'Calibration and Maintenance' and
User 1 Access
/ or 'Logging access'.

User 1's password – a unique 20-character (alphanumeric) security code. A minimum password
User 1 Password
length applies.

View / Edit Other Users Selects the other user's access levels and passwords. If selected additional fields appear:

User X Name Where X is the user number (2 to 12) – up to 20 characters can be used.

User X Access Where X is the user number (2 to 12). A dialog box is displayed listing the access available for the
user:
 Calibration & Maintenance
 Logging
 Configuration (No access)
 Configuration (Load)
 Configuration (Limited)
 Configuration (Full)

User X Password Where X is the user number (2 to 12). The password for User X.

If 'Security System' is set to 'Advanced' and a user other than User 1 is logged on, the 'User' tab has three fields.
These fields can be edited only if User 1 has set the security field 'Reconfigure preset' to 'Yes' – See page 31.
Where X is the user number (2 to 12).

User X Name User X identification tag. Up to 20 characters.

Where X is the user number (2 to 12). A dialog box is displayed listing the access available for the
user:
User X Access
 Calibration & Maintenance
 Logging

User X's password – a unique 20-character (alphanumeric) security code. A minimum password
User X Password
length applies.

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5.3.6 Messages

Fields Description

Up to 24 messages can be defined to indicate a particular event or action has occurred. These are
Messages
displayed on the chart when the relevant annotation is enabled.

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5.4 Measurement
There are three tabs in the 'Measurement' screen:

5.4.1 Setup

Fields Description

The display units for silica concentration. Three options are available:
 ppb
Display Units
 µg/l
 µg/kg

The reaction temperature range is 37 to 50 °C (98 to 122 °F) in 0.1 °C (0.18 °F) increments. The
analyzer is optimized to run at a reaction temperature of 45 °C (113 °F).

Reaction / Pre-Heat Any changes to the reaction temperature may affect analyzer performance.
Temp The pre-heater temperature range is 37 °C to 80 °C (98 to 176 °F) in 0.1 °C (0.18 °F) increments. The
analyzer is optimized for operation at a pre-heater temperature of 75 °C (167 °F).
Any changes to the pre-heater temperature may affect analyzer performance.

Enable Streams The stream(s) to be enabled for sampling.

Stream Sequence The order in which the streams are sampled.

Up Scale Time The time taken for the analyzer to measure a full step change from a low concentration sample to a
high concentration sample (12 to 60 minutes).

Down Scale Time The time taken for the analyzer to measure a full step change from a high concentration sample to a
low concentration sample (14 to 60 minutes).

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5.4.2 Streams

Fields Description

For each available stream a page opens with three fields:

 Stream 1 (2 to 6) Tag – adds an identification for the current stream.
 Range Low – sets the low range value (0 to 5000 ppb).
Stream 1 to 6
 Range High – sets the high range value (0 to 5000 ppb).

If the difference between the low and high value is too small, the trace displayed appears very noisy.
The difference between the low and high value must be at least 50 ppb.

5.4.3 Diagnostics

Fields Description

The Reagent Bottle Capacity can be set between 0.1 and 10.0 liters. This should be changed only if
Reagent Bottle Capacity the initial volume of each reagent installed is not 2.5 liters.
This value is used to predict the level of reagent remaining in the bottle.

The early warning alarm point for the reagent solutions. Can be set between 1 and 30 days.
Reagent Limit
Set to a suitable interval to allow new reagents to be ordered.

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5.5 Alarm Relays

Concentration

Hysteresis
Trip Point
Hysteresis
Concentration
Alarm On Alarm On

Alarm Off

Alarm switches Alarm switches

off automatically off automatically

High Alarm Action Low Alarm Action

Fig. 5.3 High / Low Process Alarms

Concentration

Hysteresis
Trip Point
Hysteresis

Concentration
Alarm On Alarm Latched Alarm On Alarm Latched

Alarm Off Alarm

Off
Earliest point that Alarm Earliest point that Alarm
the alarm can be acknowledged the alarm can be acknowledged
acknowledged by operator acknowledged by operator

High Latch Alarm Action Low Latch Alarm Action

Fig. 5.4 High / Low Latch Alarms

Concentration

Hysteresis
Trip Point
Hysteresis

Concentration
Alarm On Alarm On

Alarm Off

Alarm Alarm switches Alarm Alarm switches

acknowledged off automatically acknowledged off automatically
by operator by operator

High Annunciate Alarm Action Low Annunciate Alarm Action

Fig. 5.5 High / Low Annunciate Alarms

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There are six tabs in the Alarm Relays screen, one for each alarm:

Fields Description

Each of the six alarms can be configured independently to one of the following sources:
 None – no other fields are visible
Alarm Source
 Stream 1 to Stream 6
 Cleaning in progress

If 'Alarm Source' is set to Stream X, additional fields appear:

If 'Alarm Source' is set to Stream X, the alarm type can be set to:
 High / Low process – see Fig. 5.3, page 36.
 High / Low latch – see Fig. 5.4, page 36.
Alarm Type
 High / Low annunciate– see Fig. 5.5, page 36.
 Out of sample – the alarm state is active if an out-of-sample condition occurs in the selected
stream source.

Alarm Tag The Alarm identification tag – up to 20 characters.

Trip The value at which the alarm is to activate (0 to 5000 ppb).

When an alarm trip value is exceeded, the alarm does not become active until the time hysteresis
value has expired. If the signal goes out of the alarm condition before the time hysteresis has expired,
Hysteresis the hysteresis value is reset – see page 36 for hysteresis actions.
The hysteresis value is set in concentration units (0 to 5000 ppb), and the hysteresis time is set in
seconds (0 to 5000 s).

If set to 'Yes' the alarm relay is normally energized and is de-energized when an alarm condition
occurs.
Fail Safe
If set to 'No' the alarm relay is normally de-energized and is energized when an alarm condition
occurs.

If set to 'On' all changes in the alarm state in the Alarm Event log are recorded – see Section 9.5.2,
Log Enable
page 59.

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5.6 Current Outputs

There are six tabs in the Current Outputs screen, one for each output:

Fields Description

The 'Output Source' field has several options:

Output Source  None. No other fields are visible
 Stream 1 to Stream 6 – Additional fields appear

The high and low limits for the output range. Both values can be set independently (0 to 5000 ppb).
Output Range
If the difference between the zero and span is too small, the output is very noisy.

The electrical high and low limits (0 to 22 mA).

Output Type For example, if the output range is set to 0 to 2000 ppb and the 'Output Type' to 4.00 to 20.00 mA,
at 0 ppb the output is 4.00 mA and at 2000 ppb the output is 20.00 mA.

Out of sample indicator. If set to 'Yes', the output goes to the default output value when an out of
Out of Sample Ind.
sample condition occurs for the selected stream source.

Default Output The output value used when an out of sample condition occurs and 'Out of Sample Ind.' is set to
'Yes' (0 to 22 mA).

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5.7 Logging
There are three tabs in the 'Logging' screen:

5.7.1 Recording

Fields Description

The frequency (up to 720 minutes) at which stream data is recorded to the analyzer's internal
Sample Rate
memory and the SD card (if fitted).

5.7.2 Chart

Fields Description

The orientation and direction of the chart display. Options are:

 Horizontal -->
Chart view enable
 Horizontal <--
 Vertical

Enables chart annotations to be visible. Options are:

 None
Chart annotation
 Alarms
 Alarms & Operator Messages

Chart divisions The major and minor chart divisions.

Trace pointers Toggles the trace pointers on / off.

Screen interval The amount of data shown on the screen.

Trace width The width of each trace in pixels (1 to 3).

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5.7.3 Archive

Used to configure the data that is to be recorded on the SD card – see Section 9, page 55.
When external archive media contains approximately 300 files, its read / write performance becomes too slow, archiving is stopped
automatically and the icon is displayed alternating with the icon. In this condition, data continues to be recorded on the
internal memory. Replace the SD card with an empty card to prevent loss of unarchived data.

Fields Description

Archive file format The file format that archive files saved as.
Toggles between 'Text Format' and 'Binary Format'.

Archive file enables At least one of these options must be selected for data to be archived automatically to an SD Card.
A dialog box is displayed showing the log files that are to be recorded:
 Text format file containing the stream data.
 Binary format file containing stream data.
 Alarm event log file enable (*.e)
 Audit log file enable (*.a)

New file interval Available only if 'Wrap' is set to 'Off' and text format is selected.
The interval that text format stream data files are created. Options are:
 Off
 Hourly
 Daily
 Monthly

Wrap If set to 'On', the oldest archived data on the SD card is deleted automatically when the SD card
approaches its maximum capacity.
If set to 'Off', archiving stops when the SD card is full. The analyzer continues to store data internally
– see Section 9, page 55. When an empty SD card is inserted, archiving continues from the point
that the last archive was made.

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5.8 Communications
There are three tabs in the I/O modules screen:

5.8.1 Ethernet

Configures the way that the analyzer can be accessed via an Ethernet network – see Appendix E, page 81.

Note. Changes to the 'IP-address', 'Subnet mask' and 'Default Gateway' parameters are implemented only after the analyzer
has been restarted. Change the addressing parameters, exit and save the configuration, then power down and restart the
analyzer.

Fields Description

The IP-address to be assigned to the analyzer. The IP address is used by the TCP/IP protocol to
IP-address distinguish between different devices. The address is a 32 bit value expressed with four values (0 to
255), each separated by a period (.).

The subnet mask is used to indicate which part of the IP address is for the network ID and which is
Subnet mask for the host ID. Set each section that is part of the network ID to 255.
For example, 255.255.255.0 indicates first 24 bits are for the network ID.

The IP address for the 'Default gateway' (for example, router, switch) required to communicate with
Default Gateway other networks.
The default setting is '0.0.0.0'

Enables up to four users to access the analyzer via the internet. A dialog box is displayed with four
options:
 User name – the name of user granted FTP access (up to 12 characters).
 Password – the password required for FTP login (up to 12 characters).
FTP user 1 to FTP user 4
 Access Level – toggles between 'Full' or 'Read-only' access.
 Remote Operation – toggles between 'None', 'Operator' or 'Configuration'.
Note. If a user is given full access via FTP, that user is able to select from the saved
configuration files in the analyzer.

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5.8.2 email 1 and email 2

The analyzer can be configured to send emails to a maximum of 6 recipients in response to certain events. The addressees can all
subscribe to the same SMTP server or the analyzer can be configured to send emails via 2 different SMTP servers to a maximum of 3
addressees per server.
Up to 10 independently configurable triggers may be enabled to generate an email when the selected source becomes active. When
a trigger source becomes active, an internal 1 minute delay timer is started. At the end of that minute, an email is generated that
includes, not only the event that initiated the delay timer, but every other event that occurred during the delay period together with any
enabled reports. The data returned in the email therefore reflects the real-time alarm state at the time the email was generated, not
the state when the first trigger source became active.
Each email sent includes a link to the analyzer's embedded web server, enabling the analyzer's data and status to be viewed remotely
using an internet browser on a PC.

Fields Description

SMTP Server IP Address The IP address of the SMTP server through which emails are to be routed.

Recipient 1 to Recipient 3 The email address of recipient 1 to 3.

Inverted Triggers The option to invert triggers 1 to 6.

The trigger for an email message to be sent. A dialog box is displayed with three options:
 None – no triggers are set.
 Archive state – a dialog box is displayed with six options:
– Archive media not present
– Too many files on the archive media
– Archive media 100% full
– Archive media 80% full
– Archive media present
– Archive on-line

Trigger 1 to 10  Event group – a dialog box is displayed with nine options:

– Solutions (reagent, cleaning solution, secondary solution is low or out)
– Samples (out of one or more samples)
– Optics (faulty optics)
– Temperatures (control block / electronics out of limits)
– Power (excessive current)
– Calibration (factor / offset error or missed calibration)
– Hardware (temperature sensor, analog-to-digital converter 1 to 3 failures)
– Service (service due / media card full)
– Alarm Relays (alarm relay active)

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6 Start-up
6.1 Commissioning the Analyzer
7. Purge the zero calibration line and the secondary and
Warning. clean solution lines as follows:
Protective eye wear and protective hand wear must be worn a. Press the key, select 'Calibration & Maintenance'
when contact with chemicals is possible. Take appropriate and select the 'Manual Test Settings' button.
Health & Safety precautions.
b. Select 'Test Pumps' and increase the sample pump
speed to 5 rpm using the key pad.
Refer to Appendix A for details of reagents, calibration solutions
and cleaning solutions. c. Exit the 'Test Pumps' page and enter the 'Test Valves'
page.
Before operating the analyzer:
d. Select 'Cleaning ON' to energize the clean valve.
1. Ensure the analyzer has been installed correctly – see Leave on for at least 1 minute to flush the clean
Section 4, page 15. solution line.
2. Ensure all reagent, calibration and cleaning solution e. De-energize the clean valve and energize the
bottles are filled with the appropriate solutions. secondary calibration valve in the 'Test Valves' page.
3. Ensure the reagent bottles are mounted safely and Leave on for a least 1 minute to flush the secondary
securely in the trays* (if supplied) and the bottle tops are solution line.
fitted securely. f. De-energize the secondary calibration valve and
energize the zero cal valve. Leave on for at least 30
*These accessories are not included with all models. seconds.
6.1.1 Start-up and Configuration g. Once all lines have been flushed, select 'Normal Mode'
The following steps describe briefly how to start up and to exit 'Manual Test Settings'. The analyzer returns to
configure the analyzer prior to operation: the correct pump speed and de-energizes the valves.
1. Clip the pump plattens into place. h. A recovery period is initiated (this can be dismissed to
2. Ensure at least one sample stream is connected and access the menu).
flowing.
8. Press the key, select 'Calibration & Maintenance' and
3. Ensure the drain tube from the analyzer is: select 'Solution Replacement'. Select 'Replace Cleaning
a. connected and directed to a drain Solution' and then 'Replace Secondary Cal Solution' – this
updates the dates they were installed.
b. as short as possible and routed as vertically as
possible. 9. Select 'Replace All Reagent Solutions' – this initiates a
purge sequence followed by a recovery sequence that
4. Switch on power to the analyzer. enables the analyzer to stabilize.
5. After the initial power up procedure a message is 10. Initiate a Manual Clean procedure.
displayed asking if the 'Power Up Sequence' should be
aborted. Select 'Stop' to abort the automatic start up. At this stage a baseline calibration must be performed.
6. Check that the failure icon ( ) is not displayed in the
diagnostic window. If it is displayed, resolve the cause of Note. The analyzer reading takes some time to settle after
the failure before proceeding. the initial Commissioning procedure – this is due mainly to
the gradual wetting of the internal plastic flow path.
Therefore, if an accurate calibration is required it is advisable
to wait several hours before initiating a calibration.

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6.2 Performing a Baseline Calibration

Note.
 Before starting the initial Baseline calibration, it is
important to check the reagent lines are fully purged
and there is no air flowing through the reaction block.
 Check there are no air bubbles in the cuvette by
checking the stability of the 'Measure Detector mV'
signal in the 'Measurement Status' / 'Diagnostic
Information' page.
If the signal is moving by more than 20 mV over a 30
second period, air may still be present in the cuvette.
Initiate a manual clean sequence.

To perform a Baseline calibration:

1. Press the key and select 'Calibration & Maintenance'
in the menu.
2. Select the 'Calibration' button and press the key.
3. Change the 'Secondary Calibration' value to match the
concentration of the secondary calibration solution being
used.
4. Start a 'Baseline Calibration'.
The 'Baseline Calibration' window is displayed:

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7 Calibration & Maintenance

Invalid
Password

Password
Required
(if set)

Valid
Password
No Password
Required

Setup Calibration / Clean – see Section 7.4, page 48

Calibration – see Section 7.5, page 49
Solutions Replacement – see Section 8.1.2, page 51
Annual Service – see Section 8.1.3, page 51
Manual Test Settings – see Section 8.4, page 54

Fig. 7.1 Calibration & Maintenance Overview

A full two-point calibration of the analyzer is performed by running an internally-generated zero calibration and replacing the sample
automatically with a secondary calibration solution of a known concentration.

Fig. 7.2 Calibration Progress

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7.1 Zero Calibration

During the zero calibration the sample is diverted from its normal flowpath by the Auto Zero valve into the second mixing stage. The
pH value at this point is too low to allow the silica-molybdate reaction to take place, consequently a solution equivalent to a zero silica
concentration is produced. During the zero calibration the system continues to allow the first acid and molybdate solutions (reagents
1 and 2) to flow, allowing the silica content of these reagents to react and therefore be compensated for in the final measured silica
value.

Reacted sample to optical unit

Temperature controlled at 45 ° C (167F)

Production of blue
molybdosilicic acid complex

1 Minute
0.8 to 1.0 pH providing reducing conditions
to stop formation of yellow complex Reduction Solution

2 Minutes
1.4 to 1.8 pH providing conditions for the Second Acid
production of yellow ß-molybdosilicic acid
2 Minutes
Molybdate
Small quantity of
SiO2 in reagents
First Acid
Sample
Auto-zero valve

Fig. 7.3 Chemical Schematic During a Zero

Each time the reagents are replenished, a BASELINE

CALIBRATION is initiated. During the Zero calibration section,
Display and Reading ppb SiO2

the background offset is compensated for and the Zero Offset

parameter is set to 0.0ppb. In a Baseline Calibration the Zero
section is always followed by a Secondary Calibration.
Theoretical Response During continuous running the analyzer exhibits a certain
Calibration Factor 1.0 amount of drift (that usually affects the zero calibration) due to:
 changes in the reagent solutions
 'dirtying' of the cuvette windows.

If this is not compensated for, by carrying out regular

calibrations, significant inaccuracies can be introduced.
Absorbance
Baseline Zero Offset 2 ppb The degree of zero drift is indicated by the Zero Offset – see
Fig. 7.4.
Fig. 7.4 Zero Calibration

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7.2 Secondary Calibration

The zero, secondary and zero & secondary sequences can be
100 % initiated manually or at programmed intervals.
Theoretical Response –
Display and Reading ppb SiO2

Calibration Factor 1.0 Table 7.1 shows the timings for the full calibration sequence.

Secondary Recovery
Zero Normal
Activity Cal (introduce
(if required) Operation
(if required) sample)

Analyzer Response Valve

Zero Secondary None None
Calibration Factor 0.9 Energized

Timing
(minutes) 36 24 18 N/A
Default
0%
Absorbance Calibration
Zero Offset – Energized Energized Energized De-energized
Baseline Relay
2 ppb
Table 7.1 Calibration Sequence
Fig. 7.5 Secondary Calibration
7.3 Cleaning
The analyzer can be programmed to introduce an alkaline
During the Secondary calibration a known value silica
cleaning solution through the normal solution flowpath
(secondary) standard is passed through the normal sample
automatically.
flowpath, allowing a full chemical reaction to take place. The
silica chemistry is so reproducible that this response can be The alkaline solution has 2 main functions:
compared to a theoretical response built into the analyzer. The
 to remove the build up of precipitation or deposits in the
theoretical response has an ideal calibration factor of 1.0.
system due to the acidic chemistry conditions inside the
If the response is not perfect, compensation is applied to make reaction block and optical unit. If cleaning is carried out
the readings correct and the resulting Calibrating factor provides frequently, build up, and its effects on the zero offset, are
an indication of how much compensation is required – see minimized.
Fig. 7.5.
 to keep all the surfaces very clean and wetted, reducing
If this is within acceptable limits, the calibration passes and the the effects of bubble formation due to sample and reagent
necessary compensation is applied. If the results are outside degassing.
acceptable limits the analyzer shows a calibration fail.
Cleaning can be initiated either manually or automatically at
Calibration options comprise:
pre-programmed intervals with an adjustable duration.
 Baseline (2-point, resets zero) – runs both a zero and a
The ideal frequency and duration of cleaning is determined by
secondary calibration. Perform this routine only after the
monitoring the zero offset parameter at the end of each
reagents have been replaced or after an annual service.
calibration sequence. If the zero offset is not increasing by more
This routine can only be initiated manually.
than 1 ppb from one zero calibration to the next, cleaning can
 Zero (1-point) – required to compensate for any zero drift. be less frequent.
Performed weekly or as required to ensure accurate silica
The recommended initial starting point is to clean frequently for
measurement.
a short period, for example, weekly for 30 minutes.
 Secondary (1-point) – to verify sensitivity (as required) or if
the secondary calibration solution has been replaced.
 Zero & Secondary (2-point) – can be performed instead of
a weekly zero calibration to compensate for drift and verify
sensitivity.

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7.4 Setup Calibration / Clean

Enables scheduled calibration and cleaning.

Fields Description

The automatic calibration schedule for the analyzer. A dialog box is displayed with the following options:
 Zero Frequency – the frequency zero calibrations are performed (off to 7 days).
 Next Zero – if 'Zero Frequency' has been enabled, this displays / sets the scheduled date for the
zero calibration. Once a scheduled calibration has been performed the date is incremented by the
number of days set in 'Zero Frequency'.
Important. A warning is displayed if the Next Zero is scheduled 6 hours (or less) after an
automatic clean. It is recommended that an automatic clean and zero are separated by 6 hours to
ensure the best zero accuracy; this also applies to manually triggered functions.
 Secondary Frequency – the frequency secondary calibrations are performed (off to 4 weeks).
 Next Secondary – if 'Secondary Frequency' has been enabled, this displays / sets the scheduled
Automatic Schedule date for the secondary calibration. Once a scheduled calibration has been performed the date is
incremented by the number of days set in 'Secondary Frequency'.
Important. A warning is displayed if the 'Next Secondary' is scheduled 6 hours (or less) after an
automatic clean. It is recommended that they are separated by 6 hours to ensure the best
calibration accuracy; this also applies to manually-triggered functions.
 Clean Frequency – the frequency the analyzer is cleaned (off to 4 weeks).
 Next Clean – if 'Clean Frequency' has been enabled, this displays / sets the scheduled date for
analyzer cleaning. Once a scheduled clean has been performed the date is incremented by the
number of weeks set in 'Clean Frequency'.
 Manual Clean – to ensure zero accuracy, perform a zero at least 6 hours after the clean
sequence has completed.

The value of the secondary calibration solution used (10 to 5000 ppb) – see Appendix A.2, page 66.
Secondary Calibration
Value Important. This is the same value that is used in the 'Calibration' options – see Section 6.2. Changing
the value here also changes the value in the 'Calibration' options.
Automatic Scheduled The duration used in scheduled automatic cleans (20, 30, 60 minutes, 2, 4, 6, 8, 12 hrs). See Note.
Clean Duration

Manual Clean The duration used when a manual clean is initiated (20, 30, 60 minutes, 2, 4, 6, 8, 12 hrs). See Note.
Duration

Reset Cal. Factor & Immediately resets the calibration factor and the calibration offset to the default factory setting. This
Offset option can be used when a calibration has not been performed correctly.

A non-adjustable clean duration is used automatically when the analyzer is returned to service following out-of-service conditions
such as excessive zero offset, power loss for more than 24 hours and loss of sample for more than 24 hours.
Note. All Cleans are followed by an 18 minute recovery period.

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7.5 Calibration
Enables manual calibrations to be performed.

Fields Description

The value of the secondary calibration solution used (10 to 5000 ppb)
Secondary Calibration – see Appendix A.2, page 66.
Value Note. This is the same value used in the 'Setup Calibration / Clean' options. Changing the value here
also changes the value in the 'Setup Calibration / Clean' options.

If the analyzer does not have any active alarms or warnings that can affect a calibration, the following options are available:

Both a zero and a secondary calibration are performed. A new calibration factor is calculated and the
Zero Offset is reset to 0.0 ppb. A recovery period follows.
Baseline (2 point, resets
A baseline calibration must be performed when the reagents have been replaced or an annual
zero offset)
service has been performed.
A progress bar is displayed indicating the maximum time required for the operation.

A zero calibration is performed and a new zero offset calculated. The recovery period follows.
Zero (1 point)
A progress bar is displayed indicating the time required for the operation.

A secondary calibration only is performed and a new calibration factor calculated. A recovery period
Secondary (1 point) follows.
A progress bar is displayed indicating the time required for the operation.

Both a zero and secondary calibration are performed. A new zero offset and calibration factor are
Zero & Secondary calculated. A recovery period follows.
(2 point)
A progress bar is displayed indicating the time required for the operation.

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8 Maintenance
8.1 Scheduled Maintenance
Warning.
8.1.1 Chemical Solutions
 Ensure personal protective equipment (PPE) such as Reagent, calibration and cleaning solutions are necessary to
gloves and eye protection are worn during any maintain the analyzer in operation. Use the bottles supplied. If
maintenance and that any spillages are cleaned-up solutions are stored, keep them in polythene bottles with tightly
using clean water. fitting tops.
 To familiarize yourself with handling precautions,
dangers and emergency procedures, always review Caution. Avoid contamination of the solutions.
the Material Safety Data Sheets prior to handling  When replacing solutions, the reagent and standard
containers, reservoirs, and delivery systems that solution bottles must be emptied and rinsed with high
contain chemical reagents and standards. purity water before re-filling.
 Take care if cleaning any spillages and observe all  Do not top solution bottles up, always refill them.
relevant safety instructions – see Section 1, page 3.
 Bottle tops must be fitted to keep out dust (dust can
 Clean the analyzer using a damp cloth only; mild be a source of silica).
detergent can be used as a cleaning aid. Do not use
Acetone or any organic solvents.  Analyzer performance relies heavily on the integrity of
these solutions, so it is very important to prepare,
 Isolate electrical components before maintenance or store and handle them with care.
cleaning.
 Observe all health and safety procedures for handling Take care when storing the bottles. Ensure they are date
chemicals – see Section 1, page 3. stamped, used in strict rotation and not used after the expiry
date. Take care to avoid spillages if solutions are transferred
from bulk containers to the analyzer's own bottles. Any spillages
Note. Due to the specialized nature of this type of analyzer, must be diluted with water and flushed to drain.
maintenance must be performed only by qualified
personnel. Training can be provided by the Company via a For information about reagent solutions refer to Appendix A,
network of local or overseas agents, or may be performed page 66.
on the users' premises.

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8.1.2 Solution Replacement 8.1.3 Annual Service

The analyzer has predictive capability that notifies when the The analyzer is taken offline and the pumps are stopped when
solutions require changing. For details of the reagent, clean and an annual service is in progress.
calibration solutions, refer to Appendix A, page 66.
The annual service requires the pump tubing and all capstans to
The analyzer is taken offline when solution replacement is in be replaced. Once the service has been completed, the last
progress. annual service date is reset and a purge routine is run
automatically. After each annual service, perform a manual clean
Note. To prevent air getting into the reagent lines, ensure and, 6 hours later, a baseline calibration.
the peristaltic pumps are switched off prior to lifting the It is recommended that the pump tubing and pump capstans in
reagents lines out of the reagent bottles. This is done either the annual pump refurbishment kit are replaced after one year of
automatically by entering the solution replacement page or operation.
manually through the Manual Test Settings menu.

Fields Description

Prompts for the reagents to be changed.

When all reagent solutions have been
changed, the analyzer purges the reagent
Replace All lines so that the fresh reagent solutions enter
Reagent the reaction coil. The analyzer then goes
Solutions through a recovery sequence and then
prompts the user to instigate a calibration. A
Baseline calibration must be carried out after
replacing reagent solutions.

Replace Prompts for the secondary calibration

Secondary solution to be changed. Once changed the
Cal. date of the replacement in the Diagnostic
Solution Display is reset.

Prompts for the cleaning solution to be

Replace
changed. Once changed the date of the
Cleaning
replacement in the Diagnostic Display is
Solution
reset.

Opens the 'Calibration' window – see

Section 7.5, page 49 to enable the analyzer
Calibration
to be re-calibrated by running a Baseline
calibration routine.

Fig. 8.1 Pump Tubing and Capstan Replacement

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Referring to Fig. 8.1: 11. Ensure the tubing is aligned correctly over the rollers.
1. Unlock catch A, use handle B to slide the analytical 12. Refit the platens C and pump end plate F.
section forward and lock it into place using catch A.
2. Release the pump tube clips on the downstream side to Note. When fitting the pump end plate, ensure the
prevent back-siphoning of reagents (and possible shaft / bearing adaptor engages with the central hole
contamination of solutions in the bottles) when platen C in the pump shaft and that the pivot pin aligns with the
is unlatched. mating hole in the pump end plate F.

3. Using a screwdriver, remove capstan screw D and

washer E, 13. Refit washer E and capstan screw D.

4. Remove pump end plate F (pull off squarely), ensuring Tighten screw D and clip each platen C into place:
that the shaft-to-bearing adaptor is not lost.
5. Unlatch and rotate each platen C, to access the pump
tubing. Slide the platens off the pivot pin.
6. Unlatch the other side of the pump tubing G and discard
the tubing.
7. Slide off and discard each capstan H.
8. Replace each capstan. Ensure the capstans are aligned to
maximize mixing effectiveness.
9. If not already fitted, clip cover I to the outer capstan.
10. Clip the new tubing into place. Ensure the correct tubing is
used for each pump and the seals are in place:
Rear 14. Unlock the analytical section and slide it back into the
Green Brown normal operation position. Lock the analytical section into
Blue Orange place.
Front Violet
Gray Red For part numbers, refer to the Spares section – see Appendix H,
page 87.
Wet the mating surfaces with demineralized water and Once the service has been completed, the annual service date
squeeze between the two points shown below to ensure is reset and a purge routine is run automatically to purge the
that tubing clips into place correctly: system of air. After the purge sequence, perform a Baseline
calibration.

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8.2 Periodic Maintenance

8.2.1 Sample Filter Replacement
The sample filter prevents large particles from entering the wet 8.2.2 Reagent Tube Filter Replacement
section. Filter longevity is related to the level of particulates in the Each reagent tube has an integral filter fitted into the sinker.
samples.
Warning.
 Ensure that gloves and goggles are worn during any
maintenance and that any spillages are cleaned up
using high-purity water.
 Observe all health and safety procedures for handling
A chemicals.

E
D

Fig. 8.2 Sample Filter Replacement

To replace the sample filter:

1. Press the key. The main menu is displayed:

Fig. 8.3 Reagent Tube Filter Replacement

To replace the reagent tube filter:

1. Press the key. The main menu is displayed:

2. Using the and keys, highlight 'Start / Stop Pumps'

and press the key.
3. Referring to Fig. 8.2:
a. Remove cap A from filter holder B.

Note. Do not remove the sample tubing from

connector C.
2. Using the and keys, highlight 'Start / Stop Pumps'
and press the key.
b. Using a suitable tool, remove filter D from filter
holder B. 3. Referring to Fig. 8.3:
c. Wet the new filter with demineralized water and fit it a. Remove cap A from reagent or solution bottle B.
into the holder. b. Using a suitable tool, remove filter C from sinker D.
d. Wet O-ring E with demineralized water and refit c. Fit a new filter.
cap A to filter holder B.
d. Reposition the reagent tube in reagent bottle B and
4. Start the pumps and check that the sample solution is refit cap A.
flowing. If there is air leaking into the filter housing, tighten
the filter cap onto the filter holder. 4. Start the pumps.

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8.3 DC Fuse Replacement 8.4 Manual Test Settings

This function is used to aid troubleshooting – see Appendix C,
Caution. Only use replacement fuse: 12.5 A 125 V DC page 75.
Type T, SCHURTER, Model SPT 5 x 20 Series The analyzer is taken offline when Manual Test Settings are
used. On exiting Manual Test Settings it is possible to exit via
Normal Mode and Test Mode. On exiting 'Normal' mode the
settings revert to the default settings.
Exiting via Test Mode maintains the settings entered while in
Manual Test Settings so that the readings can be monitored
after changes have been made.

8.5 Start / Stop Pumps

This function is available on the first menu and is used to stop
and start the peristaltic pumps manually for maintenance
purposes.

Fig. 8.4 Replacing the DC Fuse

Warning. Isolate the analyzer and cables from electrical

supply before accessing the DC fuse.

Referring to Fig. 8.4:

1. Turn door retaining screws A1/4 turn counter-clockwise
and open the electronics section door.
2. Using a cross-head screwdriver, remove 4 screws B and
remove transparent cover plate C.
3. Carefully remove the fuse from fuse holder D on DC
power board E.
4. Fit a new fuse (12.5 A 125 V DC Type T, SCHURTER,
Model SPT 5 x 20 Series) into fuse holder D on DC
power board E.
5. Refit transparent cover plate C and secure with 4 screws
B

6. Close the electronics section door and turn door retaining

screws A1/4 turn clockwise to secure.

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9 Logging

Invalid
Password Password
Required
(if set)

Valid
Password

No Password
Required

Switches internal logging on / off (Available only from the chart view)

Resets Archiving – see Section 9.2, page 57

Switches the removable media online / offline

Opens the file viewer – see Section 9.3, page 57

On-line help – Appendix D, page 80

Fig. 9.1 Recording and Archiving

Data recorded in the analyzer's internal memory can be archived

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

Note.
The amount of time that data remains in the analyzer's internal
memory depends on the sample rate and the number of  To avoid loss of archive data, always place the media
streams – see Table 9.1. Sample data can be saved to card off-line before removing it.
removable media as either binary-encoded or  The analyzer accepts SD cards with a maximum
comma-separated files. capacity of up to 4 Gb.
Additional files can also be archived:  The analyzer complies with approved industry
 Alarm event log data standards for memory cards. SanDisk Standard
Grade memory cards have been fully tested and are
 Audit log data recommended for use with ABB analyzers. Other
 Configuration files brands may not be fully compatible with this device
and therefore may not function correctly, leading to
 Screen capture images irretrievable loss of data.

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Approximate durations for continuous recording of 6 streams 9.1 SD Cards

are shown in Table 9.1 (internal storage), Table 9.2 (external There are two methods of archiving to an SD card:
storage – text format files) and Table 9.3 (external storage –
 An SD card is kept in the analyzer
binary format files).
Data is copied automatically to the SD card at set
Storage capacity of internal (Flash) memory:
intervals. The SD card is then swapped periodically for an
Capacity 1s 10 s 30 s 60 s 120 s
empty one.
Depending on how the configuration has been set, data is
8 Mb 4 days 40 days 5 months 8 months 16 months
added either to the card until it is full and then stops
Table 9.1 Internal Storage Capacity (6-Streams) archiving or the oldest data on the SD card is overwritten
by the newest.
External (archive) capacities for text format files:
Note. To set up the analyzer to archive data to an SD
Sample Rate 128 Mb 256 Mb 512 Mb 1 Gb card automatically – see Section 5.7.3, page 40.

1 second 13 days 26 days 52 days 3.5 months

It is advisable to back-up critical data stored on an SD
10 seconds 4 months 8 months 1.3 years 2.7 years card regularly. The analyzer's internal memory provides a
buffer for the most recent data so if data stored on an SD
Table 9.2 Text Formatted Archive Files (6-Streams)
card is lost, it can be re-archived – see Section 9.2,
page 57.
External (archive) capacities for binary format files:
 Data is copied to an SD card when required
Sample Rate 128 Mb 256 Mb 512 Mb 1 Gb An SD card is inserted into the analyzer and a prompt is
1 second 2 months 4 months 8 months 16 months
displayed asking the user to select the unarchived data to
be copied.
10 seconds 1.7 years 3.3 years 6.7 years 13.3 years

Table 9.3 Binary Formatted Archive Files (6-Streams)

Note. The SD card can hold a maximum of 300 separate

files. Therefore the times stated in Tables 9.2 and 9.3 are
limited if 300 files is reached.

Fig. 9.2 SD Card Removal

To access the SD Card:

1. Ensure the analyzer is offline.
2. Use a large flat-headed screwdriver to release the two
door catches A.
3. Open the door and insert the SD card B.
The red LED C is lit when the SD card is in use by the
analyzer.
4. To remove the SD card, If the red LED is lit, press the
button D and wait until the LED goes out.
5. Pull the SD card out of its socket. The SD card can then
be inserted into an appropriate card reader attached to a
PC and the data downloaded.

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When an SD card is inserted and there is <1 day (Binary format) 9.2 Reset Archiving
or <1 hour (Text format) of data in internal memory, a dialog box If 'Reset Archiving' is selected, all data in the internal memory is
is displayed giving the user the choice of putting the media re-archived to external media.
on-line or remaining offline. If no selection is made within 10
seconds, the media card is placed on-line automatically: Note. Ideally, insert a blank media storage card before
selecting this function.

To re-archive data:
1. Insert an SD card, with sufficient free space, into the
analyzer.
2. Select 'Off-line' in the menu.
3. Select 'Reset archiving' in the menu.
4. Select 'On-line' in the menu.
5. Select the data to be archived if >1 hour (Text format) or
>1 day (Binary format) of data in internal memory and
press the key.
Note. Data stored in the internal memory buffer can still be
transferred to the archive media when the archive media is
9.3 File Viewer
A prompt is displayed providing the option to view either internal
placed on-line again (providing it is not off-line so long that
or external files (if an SD card is present).
the un-archived data in the internal memory is overwritten).

When an external archive media card is inserted and there is >1

day (Binary format) or >1 hour (Text format) of data in internal
memory, a dialog box is displayed prompting the user to select
either the data to be archived or remain off-line:

Use the and keys to scroll up and down the screen.

If viewing files on the SD card, files can be deleted by
highlighting a file and pressing the key.

Select the data to be archived and press the key. A progress

bar is displayed:

The files are copied to the SD Card.

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9.4 Archive File Types 9.5.1 Data Filenames

All archive files created by the analyzer are assigned filenames Data files can be configured to contain data gathered over a
automatically. Each type of archived file is assigned a different predefined period of time ('New File Interval') – see
file extension – see also Section 5.7.3, page 40. Section 5.7.3, page 40. The 'Analyzer Tag' is set in the
configuration – see Section 5.3.1, page 28.
Archive files are created as either:
 Hourly filename
 Text format data files
<hour> <day, month, year> <analyzer tag>
or
 Daily filename
 Binary format files
<day, month, year> <analyzer tag>
File types and extensions for Text files are:
 Monthly filename
 Data files containing stream data.
<month, year> <analyzer tag>
Text files – *.D** extension
 None filename
Binary files – *.B** extension
<analyzer tag>
 Alarm event log files containing the historical record of the
alarm events related to the stream(s) plus the history of
any operator messages. Note. The time and date are formatted according to the
date format set in 'Common Configuration'.
Text files – *.E** extension
Binary files – *.EE* extension In addition to new channel data files being created according to
 Audit log files containing the historical entries from the the 'New File Interval', they are also created in the following
audit log. circumstances:

Text files – *.A** extension  The analyzer's power is lost then restored.

Binary files – *.AE* extension  The analyzer is taken offline and the archive media
removed, replaced or refitted.
9.5 Data Files  The analyzer's configuration is changed.
Text format archived data is stored in a comma-separated value
format and can be imported directly into a standard  One of the current files exceeds the maximum permissible
spreadsheet, for example, Microsoft® Excel. The files can also size.
be saved in ASCII text format.  When the daylight saving period starts or ends.
Alternatively, you can carry out detailed graphical analysis of the
data on a PC using our DataManager data analysis software. Note. The analyzer's internal clock can be configured to
adjust automatically at the start and end of 'Daylight Saving
Time' periods.

When one of the above conditions occurs, new channel data

files are created for each enabled group and the file extension
index on each new file is incremented by one from the previous
file.
If the original file had an extension of .D00, after one of the
above events a new file is created with the same filename but an
extension of .D01.

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9.5.2 Log Files 9.5.4 Filename Examples

The 'Alarm Event' and 'Audit' logs are archived into individual New file interval set to Hourly, Filename tag set to Process
files. The filenames are formatted as follows: Group 1; date is 10th October 2011; Channel data and alarm
event log files only enabled:
 Alarm Event Log filename
9:00 am new file created in which all channel data recorded
<hour, min> <dd, mm, yy> <analyzertag>.e00
between 9:00 and 9:59:59 is archived in the following file:
 Audit Log filename
09_00_10 Oct11_Process_Group_1.d00
<hour, min> <dd, mm, yy> <analyzertag>.a00
09:12am Power interrupt occurs
09:13am Power restored and new file created:
Note. The time and date are formatted according to the
Date format set in 'Common Configuration'. 09_00_10 Oct11_Process_Group_1.d01
10:00am New file created in which all data recorded between
9.5.3 Daylight Saving 10:00 and 10:59:59 is archived.
Files containing data generated during the daylight saving period 10_00_10 Oct11_Process_Group_1.d00
have '~DS' appended to the filename.
Start of daylight saving period Note.
A daily file is started at 00:00:00 on 30th March 2011 filename: Hourly files start exactly on the hour.
30Mar11AW6SIL.D00 Daily files start at 00:00:00.

Summertime starts at 2:00am on 30th March 2011 and the clock Monthly files start at 00:00:00 on the first of the month.
changes automatically to 3:00am.
The existing file is closed and a new file is created filename:
30Mar11AW6SIL~DS.D00

The file '30Mar11AW6SIL.D00' contains data generated from

00:00:00 to 01:59:59.
The file '30Mar11AW6SIL~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 2011 filename:
26Oct11AW6SIL~DS.D00

Summertime ends at 3:00am on 26th October 2011 and the

clock changes automatically to 2:00am.
The existing file is closed and a new file is created filename:
26Oct11AW6SIL.D00
The file '26Oct11AW6SIL~DS.D00' contains data generated
from 00:00:00 to 02:59:59.
The file '26Oct11AW6SIL.D00' contains data generated from
02:00:00.

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Multi-stream 10 Chart Functions

10 Chart Functions

Historical Review – see Section 10.1

Operator Messages – see Section 10.2
Chart Annotation – see Section 10.3
Screen Interval – see Section 10.4
Scales – see Section 10.5
Trace Select – see Section 10.6

Fig. 10.1 Chart Functions

10.1 Historical Review 10.2 Operator Messages

Enables an historical view of the chart. While in the historical These are messages that can be used to annotate the chart.
review screen an animated icon is displayed at the top of These can be selected from up to 24 pre-defined messages –
the screen. see Section 5.3.6, page 33. Alternately, the messages can be
user-defined.
Selecting the 'Historical Review' menu item changes the screen
to the history view – use the and keys to scroll up and Annotations can also be added remotely via the web – see
down the screen. Appendix E, page 81.
Selecting the 'Historical Review' menu item a second time gives The annotation is added to the chart at the time it is entered. For
the option of either exiting the historical review or to go to a example:
specified date / time:

An entry is also included in the Alarm Event Log.

Note. Annotations added while in 'Historical Review' are

added to the chart at the time of entry not on the chart as it
is displayed on the screen.

10.3 Chart Annotation

Use the and keys to select the date / time and use the
Toggles any operator messages and / or alarms on / off.
and keys to change the selected value.
To finish, press or press to exit without making any 10.4 Screen Interval
changes. The screen displays the chart at the selected date / Used to control the amount of data displayed on the screen. A
time. Use the and keys to scroll up and down the screen. longer screen interval displays data over a longer period of time,
a shorter screen displays a shorter period of data, but in more
detail.

Note. If the Screen interval is changed from the Chart

Function menu, the new setting is used until either power is
lost or the configuration is changed. On either event, the
Screen Interval reverts to the value saved in the Logging
Section of the main Configuration.

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Multi-stream 11 Alarm Acknowledge

10.5 Scales 11 Alarm Acknowledge

Selects the scale to be used. Up to six color-coded streams can
be displayed simultaneously and each stream can have its own To acknowledge a particular alarm, use the and keys to
scale (to set the scale, see Section 5.4.2, page 35). highlight it in the menu and press the key.

If 'Auto Scroll' is selected the scale for each enabled stream is

Note. Active unacknowledged alarms are identified by a
displayed sequentially. The displayed scale is color coded to
flashing red alarm event icon. Active acknowledged alarms
match the stream. For example:
are identified by a continuous red alarm event icon.
Red Pink
To acknowledge all active alarms simultaneously, select 'All' and
press the key.

10.6 Trace Select

Selects the traces to display.

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Multi-stream 12 Diagnostic Information

12 Diagnostic Information
Ensure that a note is made of all the information in the 12.2 System Information
Diagnostic screens when contacting the Company regarding The system information screen provides details regarding the
spares or enquires. calibration, maintenance and software release.
 Last / Next Zero Calibration – the date of the last
12.1 Reagent and Solution Levels
Displays the predicted levels of the reagent solutions, along with calibration and the scheduled date for the next – see
the approximate number of days remaining and the last date Section 7.4, page 48
that the reagents were replaced. Reagent consumption is  Last / Next Secondary Calibration – the date of the last
monitored by the analyzer and a diagnostic message appears calibration and the scheduled date for the next – see
once a lower limit (customer configurable) is reached. Also Section 7.4, page 48
displays whether the clean and calibration solutions are LOW or
 Zero Offset – a baseline calibration sets this offset to zero.
OK and the last date these solutions were replaced.
The result of a subsequent zero calibration is then
compared with the baseline to give the zero offset.
If the zero offset goes outside pre-configured limits the
calibration is not accepted and an alarm is triggered.
 Calibration Factor – the calculated value determined
during the last secondary calibration carried out. This
gives an indication of the sensitivity of the analyzer to
silica.
If the calibration factor goes outside pre-configured limits,
the calibration is not accepted, an alarm is triggered and
the actual calibration is shown here in red.
 Next Service – the due date for the next annual service –
see Section 8.1.3, page 51.
 Software Version – the software release number.
 LL App / OS / HMI App – the low level application,
operating system and human-machine interface numbers.
 IP address / MAC address – communication settings.

12.3 Measurement Status

The temperature of the electronics, the chemical reaction block
and the pre-heater are displayed along with the millivolt output
of the optical unit (measure and reference circuits).

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12.4 Valves and Pumps Status 12.5 Statistics

Displays the status of the wet section valves and pumps. Displays the highest, lowest and mean values of the sample
streams since the analyzer was either switched or the values
were reset. Press the key to reset the values.

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Multi-stream 13 Specification

13 Specification
Silica Measurement Display
Range Color*, passive matrix, liquid crystal display (LCD) with built-in
Fully user programmable 0 to 5000 ppb SiO2, minimum range 0 to 50 backlight and brightness adjustment
ppb Diagonal display area 144 mm (5.7 in.)

76800 pixel display

Measurement Modes
(a small percentage of the display pixels may be either constantly
Sample stream options
active or inactive. Max. percentage of inoperative pixels <0.01%)
multistream in 2, 4 or 6 stream configurations
Dedicated operator keys
 Group Select / Left cursor
Multi-stream performance  View Select / Right cursor
Measurement method  Menu key
Continuous chemistry with a minimum 12 minutes per stream
 Up / Increment key
measurement update.
 Down / Decrement key
Sample rate programmable between 12 minutes minimum to 60
minutes maximum.  Enter key
Response time
Minimum update time 12 minutes
Mechanical Data
Typical accuracy
Ingress protection
<±2% of reading or ±0.5 ppb (whichever is the greater) over the range
0 to 500 ppb* IP31** – Wet section (critical components IP66)
<±5% of reading over the range 500 to 5000 ppb*
IP66 – Transmitter
* Dependent on sample rate
Repeatability Dimensions
<±2% of reading or ±0.5 ppb (whichever is the greater) over the range Height 638 mm (25.1 in.) plus constant head
0 to 500 ppb bracket 186 mm (7.3 in.)
<±3% of reading over the range 500 to 5000 ppb Width 271 mm (10.7 in.)
Depth 182 mm (7.2 in.)
Solution Requirements Weight 15 kg (33 lbs)
Number
4 reagents (2.5 l bottles) Materials of construction
1 standard solution (0.5 l bottle) Electronics enclosure 20 % glass loaded polypropylene
1 cleaning solution (0.5 l bottle) Main enclosure Noryl
Lower tray 10 % glass loaded polypropylene
Reagent Consumption Door Acrylic
Continuous operation mode
2.5 l max. per 90 days Sample connections
Inlet 6 mm (1/4 in.) flexible hose connection
Outlet 9 mm (1/4 in.) flexible hose connection

** Not evaluated for UL or CB

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Environmental Data Alarms / Relay Outputs

Ambient Operating Temperature One per unit:
5 to 45 ºC (41 to 113 ºF)  out-of-service alarm relay
Sample Temperature  calibration in progress alarm relay
5 to 55 ºC (41 to 131 ºF)  calibration failed alarm relay
Sample Particulate  maintenance / hold alarm relay
<60 microns
Six per unit:
<10 mgl–1
 fully user-assignable and alarm relays
Sample Flow Rate
>5 ml/min / <500 ml/min Rating
Sample Pressure Voltage 250 V AC 30 V DC
Atmospheric
Current 5 A AC 5 A DC
Storage Temperature
–20 to 75 ºC (–4 to 167 ºF) Loading (non-inductive) 1250 VA 150 W
Ambient Operating Humidity
Up to 95% RH non-condensing
Connectivity / Communications
Ethernet connection
Electrical
Supply ranges Web server with ftp: for real time monitoring, configuration,
data file access and email capability
110 to 240 V max. AC 50/60 Hz ± 10 % (90 to 264 V AC, 45/65 Hz)
18 to 36 V DC 10A power supply typical (optional) Bus communications
Power consumption Profibus DP V1 (optional)
75 W max. – AC
100 W max. – DC Data Handling, Storage and Display
Security
Analog Outputs Multi level security: user, configuration, calibration and
6 isolated current outputs: maintenance pages
 galvanically isolated (to 500 V DC) from each other and all other
circuitry Storage
 fully assignable and programmable over a 0 to 20 mA range Removable Secure Digital (SD) card – maximum size 2 GB
(up to 22 mA if required) Trend analysis
 drives maximum 750  load Local and remote
Data transfer
SD card or FTP
Wetted Materials
PMMA (acrylic)
Approvals, Certification and Safety
PP (polypropylene) Safety Approval
PTFE cULus
PP (20% glass filled) CE Mark
PEEK Covers EMC & LV Directives (including latest version EN 61010)
NBR (nitrile) General Safety
EPDM EN 61010–1
Santoprene Overvoltage Class 11 on inputs and outputs
PTFE (15% polysulphane) Pollution category 2
NORYL
Borosilicate glass EMC
Acrylic adhesive Emissions & immunity
Meets requirements of IEC61326 for an Industrial Environment

DS/NAV6S-EN Rev. N

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Appendix A – Solutions
A.1 Reagent Solutions Choose a secondary solution concentration close to the point
where the greatest accuracy is required. Do not use solutions
Warning. containing less than 50 ppb silica because solution preparations
below this level can cause significant inaccuracy.
 Before handling containers, reservoirs and delivery
systems that contain chemical reagents and A stock solution of 1000 mg l–1 silica, SiO2, can be obtained in 1
standards, review the Material Safety Data Sheets to of the following 3 ways:
familiarize yourself with handling precautions, dangers 1. The preferred method:
and emergency procedures.
purchase a 1000 mg l–1 silica, SiO2 stock solution from a
 Take care if cleaning any spillages and observe all proprietary chemical supplier,
relevant safety instructions – see Section 1, page 3.
or
 General cleaning of the instrument must be carried
out using a damp cloth only; mild detergent can be 2. From sodium fluorosilicate:
used as a cleaning aid. Do not use Acetone or any a. Dissolve 3.133 (±0.001) g of sodium fluorosilicate
organic solvents. (Na2SiF6 – the purest grade available) in approximately
 Observe all Health & Safety procedures for handling 900 ml of high purity water. Ensure all solids have
chemicals. dissolved fully by stirring the solution for several hours.
b. Transfer the solution to a 1 liter volumetric flask and
A volume of 2.5 l of each reagent solution maintains the analyzer make up to the mark with more high purity water.
in operation for a minimum of three months. The bottles and c. Store the solution in a polythene bottle.
associated tubing are color-coded to identify each reagent.
Contact your local ABB representative for further information or
about reagent solutions. 3. From sodium metasilicate

A.2 Secondary Calibration Solutions a. Dissolve 3.530 (±0.001) g of sodium metasilicate

pentra hydrate (Na2SiO3·5H2O – the purest grade
Note. The high purity water used for diluting the standard available) in approximately 900 ml of high purity water.
solution should contain less than 1 ppb SiO2. If this is not Ensure all solids have dissolved fully by stirring the
possible to obtain and the silica concentration is known, solution for several hours.
make allowance for the background level in the high purity b. Transfer the solution to a 1 liter volumetric flask and
water when calculating the actual silica concentration of the make up to the mark with more high purity water.
standard.
c. Store the solution in a polythene bottle.

The value (in ppb) must be entered in the analyzer – see

Section 7.5, page 49. Note.
 Store all standard solutions in tightly stoppered
Note. The accuracy of the analyzer over its total range is
polyethylene bottles.
governed by the choice of the secondary standard solution
value. For example, an analyzer calibrated at 200 ppb,  The stock solutions of 1000 ppm remain stable for
would not be very accurate at 2000 ppb. approximately one year.

Contact your local ABB representative for further information

about secondary calibration solutions.

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A.3 Cleaning Solution A.3.1 Regular Cleaning Solution (for Automatic Cleaning
It is important that the internal pipework of the analyzer is Operation)
cleaned using the automatic cleaning schedule – see To prepare 1 liter of regular cleaning solution:
Section 7.4, page 48. This prevents gradual fouling by 1. Dissolve 5 g of analytical grade sodium hydroxide pellets,
molybdate precipitation in the pipework which can introduce NaOH, in approximately 600 ml of high purity water in a
errors and cause noise. plastic container. Allow the solution to cool to ambient
Regular cleaning is normally performed using a regular cleaning temperature.
solution – see Appendix A.3.1. If the pipework in the analyzer is 2. Add to the solution 1 g analytical grade di-sodium EDTA
extremely dirty or the tubing has become blocked, extra and stir to dissolve.
strength cleaning solution can be used – see Appendix A.3.2.
The analyzer may take some time to stabilize after the clean if 3. Transfer the solution to a 1 liter measuring cylinder and
the stronger solution is used. make to the mark with more high purity water. Mix well
and store in a tightly stoppered plastic bottle.
Warning. Sodium hydroxide is extremely caustic and must A.3.2 Extra Strength Cleaning Solution (for Troubleshooting
be handled with great care. Wear gloves and eye protection. and More Intense Wet Section Cleaning)
To prepare 1 liter of extra strength cleaning solution:
1. Dissolve 50 g of analytical grade sodium hydroxide pellets,
NaOH, in approximately 600 ml of high purity water in a
plastic container. Allow the solution to cool to ambient
temperature.
2. Add to the solution 5 g analytical grade di-sodium EDTA
and stir to dissolve.
3. Transfer the solution to a 1 liter measuring cylinder and
make to the mark with more high purity water. Mix well
and store in a tightly stoppered plastic bottle.

A.3.3 Safety Labels

Attach safety labels to all bottles as shown in Fig. A.1.

CORROSIVE HARMFUL CORROSIVE IRRITANT

Fig. A.1 Safety Labels

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Multi-stream Appendix B – Diagnostics and Alarms

Appendix B – Diagnostics and Alarms

B.1 Analyzer Diagnostic Information
The analyzer is programmed to display diagnostic messages to
Diagnostic Icon NAMUR Status
provide information on servicing requirements and any other
conditions that develop during operation. The following tables
list icon types, diagnostic messages, relay status (on or off) and Failure
any operations that are inhibited if the condition occurs.
Diagnostic icons conform to NAMUR 107.
The messages listed below are shown by icon type and then Check function
alphabetically. All diagnostic messages displayed on the
analyzer are added to the analyzer's audit log.
Out of specification
Note. The 'Out of Service' relay has the following fail-safe
operation:
 Normal operation – ON (energized) Maintenance required
 Out-of-Service state – OFF (de-energized)

Out-of- Cal. in Cal.

Hold
Icon Diagnostic message Service Progress Failed Inhibits
Relay
Relay Relay Relay

Monitor in Service
ON
The analyzer is operating correctly.

20 Character User-defined Alarm Tag

User-defined alarm message.

Media Card Full

The SD card used for recording is full and archiving has stopped.
1. Download the data onto a PC.
2. Replace the SD card with an empty SD card as soon as
possible.

A / D Error (1, 2 or 3)
A hardware error exists on the main board.
Power the analyzer down, wait for 10 seconds and power back up.
All calibrations
Notes. OFF ON
and cleans
 If the error persists contact your local ABB representative.
 Replacement board (see Appendix H, page 89 – part number
AW600065).

Excessive Secondary Current in Electronics

Too much current is being drawn by the system electronics in; this All calibrations
OFF ON
causes the analyzer to go into automatic shutdown. and cleans
Contact the Company or your local ABB representative.

Faulty Measurement Optics

Optical measurement out of limits.
1. Check the connection labelled 'MEASUREMENT CUVETTE' All calibrations
OFF ON
on the Interconnection Board. and cleans

2. Replace optical measurement assembly (see Appendix H,

page 88 – part number AW601110).

Table B.1 Diagnostic Information, Relay Operations and Inhibits (Sheet 1 of 6)

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Multi-stream Appendix B – Diagnostics and Alarms

Out-of- Cal. in Cal.

Hold
Icon Diagnostic message Service Progress Failed Inhibits
Relay
Relay Relay Relay

Reaction B. Temp.Sensor Failed

Pt1000 temperature sensor measurement is out of limits.
All calibrations
1. Check the connection labelled 'HEATER PT1000' on the OFF ON
and cleans
Interconnection Board.
2. If the error persists, contact your local ABB representative.

Reaction Block Temp. High / Low

>20 °C (36 °F) above or >20 °C (36 °F) below
The measured temperature is more than 20 °C (36 °F) above or
below the programmed control temperature.
If the temperature exceeds the programmed control temperature All calibrations
OFF ON
by more than 20 °C (36 °F), the analyzer enters automatic shutdown and cleans
mode and the heater supply is switched off.
1. Check that the sample and ambient temperatures are within
the quoted limits.
2. If the error persists, contact your local ABB representative.

Pre-Heat Temp.Sensor Failed

Pt1000 temperature sensor is out of limits.
1. Check the connection labelled 'PRE-HEATER PT1000' on OFF ON
the Interconnection Board.
2. If the error persists, contact your local ABB representative.

Pre-Heat Temperature High / Low

>20 °C (36 °F) above or >20 °C (36 °F) below
The measured temperature is more than 20 °C (36 °F) above or
below the programmed control temperature.
If the temperature exceeds the programmed control temperature All calibrations
OFF ON
by more than 20 °C (36 °F), the analyzer enters automatic shutdown and cleans
mode and the heater supply is switched off.
1. Check that the sample and ambient temperatures are within
the quoted limits.
2. If the error persists, contact your local ABB representative.

Internal Communications Failed

Communication failure between the main board and the display
assembly.
1. Check the ribbon cable connection of the main board.
2. Contact your local ABB representative.

Internal Electronics Temperature Too High / Low

The internal temperature of the electronics enclosure is either too
high or too low.
1. Check the 'Electronics' value displayed on the 'Measurement All calibrations
OFF ON
Status' page within 'Diagnostic Information' – see and cleans
Section 12.3, page 62.
2. Check that the ambient temperature is within quoted limits.
3. Contact your local ABB representative.

Table B.1 Diagnostic Information, Relay Operations and Inhibits (Sheet 2 of 6)

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Multi-stream Appendix B – Diagnostics and Alarms

Out-of- Cal. in Cal.

Hold
Icon Diagnostic message Service Progress Failed Inhibits
Relay
Relay Relay Relay

Non-Volatile Memory Error

There is a problem with either the display electronics or the main Scheduled
board memory. zero and
OFF ON
1. Power the analyzer down, wait for 10 seconds and power secondary
back up. calibrations

2. If the error persists, contact your local ABB representative.

Calibration Factor Too High / Low

A secondary calibration failure has occurred because the calibration
factor is less than or greater than the acceptable limit programmed.
1. On the 'Calibration' page, check that the secondary
calibration value has been entered correctly.
2. Remake the secondary standard. Use a higher value solution OFF ON Scheduled
if possible, as this is easier to make with less chance of secondary
errors. calibrations

3. Replace the reagents with a fresh batch, especially if this

message appears after the first calibration following the
reagent replacement (applicable to low calibration factor
only).

Reaction Block Temp Stabilising

This message is displayed at startup and remains until the reaction
block temperature has stabilized to within 2 ºC (3.6 ºF) of the
programmed control temperature. If the message is still displayed
after 15 minutes:
1. Check that the sample and ambient temperatures are within
the quoted limits. ON OFF

2. Check the 'Heater' value displayed on the 'Measurement

Status' page within 'Diagnostic Information' – see
Section 12.3, page 62.

If the temperature is low, check the heater LED on the main board is
lit. If it is not, contact your local ABB representative.

Reaction Block Temp. High / Low

>2 °C (3.6 °F) but <20 °C (36 °F) above or below
The measured temperature is more than 2 °C (3.6 °F) but less
than 20 °C (36 °F) above or below the programmed control All calibrations
OFF OFF
temperature. and cleans
1. Check that both the sample and ambient temperature are
within the quoted limits.
2. If the error persists, contact your local ABB representative.

Table B.1 Diagnostic Information, Relay Operations and Inhibits (Sheet 3 of 6)

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Multi-stream Appendix B – Diagnostics and Alarms

Out-of- Cal. in Cal.

Hold
Icon Diagnostic message Service Progress Failed Inhibits
Relay
Relay Relay Relay

Preheater Temp Stabilising

This message is displayed at startup and remains until the preheater
temperature has stabilized to within 10 ºC (18.0 ºF) of the
programmed control temperature. If the message is still displayed
after 15 minutes:
1. Check that the sample and ambient temperatures are within
the quoted limits. ON OFF

2. Check the 'Pre-Heater' value displayed on the 'Measurement

Status' page within 'Diagnostic Information' – see
Section 12.3, page 62.

If the temperature is low, check the heater LED on the main board is
lit. If it is not, contact your local ABB representative.

Pre-Heat Temperature High / Low

>10 °C (18 °F) but <20 °C (36 °F) above or below
The measured temperature is more than 10 °C (18 °F) but less
than 20 °C (36 °F) above or below the programmed control All calibrations
ON OFF
temperature. and cleans
1. Check that both the sample and ambient temperature are
within the quoted limits.
2. If the error persists, contact your local ABB representative.

Excessive Zero Offset

The zero offset parameter generated at the last zero calibration is
outside of the alarm limits. A system clean is automatically initiated
and another zero calibration is performed.
If the message is displayed after the second zero calibration:
Scheduled
1. Check the 'Audit Log' to see if a baseline calibration was
OFF ON zero
carried out after the reagents were replaced. If not, carry out
calibration
a baseline calibration.
2. At the 'Calibration and Maintenance' level, select 'Manual
Test Settings', 'Test Valves' and energize the 'Zero Cal.' valve
(set the parameter to 'On'). Check that the 'Zero Cal.' LED on
the main board is lit and that there is an audible click when
the valve energizes.

Scheduled Zero Cal. Missed

The scheduled zero calibration has been missed due to either a
manual operation being performed or an out-of-service condition.
 The next calibration due date is updated automatically.
 The next calibration is performed at the correct date and time
if the analyzer is in service

Solution Replacement Scheduled

OFF ON calibrations
The analyzer is shut down while solution is replaced.
and cleans

Scheduled Secondary Cal. Missed

The scheduled secondary calibration has been missed due to either
a manual operation being performed or an out-of-service condition.
 The next calibration due date is updated automatically.
 The next calibration is performed at the correct date and time
if the analyzer is in service.

Table B.1 Diagnostic Information, Relay Operations and Inhibits (Sheet 4 of 6)

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Multi-stream Appendix B – Diagnostics and Alarms

Out-of- Cal. in Cal.

Hold
Icon Diagnostic message Service Progress Failed Inhibits
Relay
Relay Relay Relay

No Valid Streams Available

None of the enabled streams are present, but there are samples
available to the analyzer that are currently disabled. OFF ON
Analyzer measurements are not updated but all automatic
functionality continues as normal.

Cleaning In Progress
Scheduled
A clean routine is being run.
OFF ON calibrations
A progress bar on the cleaning page indicates the time to and cleans
completion.

Calibration In Progress
A calibration routine is being run. A progress bar indicates the time
to completion. Scheduled
ON calibrations
1. Wait for the routine to be completed. and cleans
2. Cancel the routine and allow the analyzer to complete the
recovery routine.

In Annual Service
The analyzer has been taken off-line for the annual service. Scheduled
OFF ON calibrations
Complete the servicing tasks and press the key when finished
and cleans
to reset the annual service alarm and place the analyzer on-line
(after a purge and recovery period).

In Manual Test Setting

The analyzer has been taken off-line while manual test settings are
checked / adjusted. Scheduled
1. Complete the manual test settings routine. OFF ON calibrations
and cleans
2. When completed, place the analyzer back on-line by exiting
via 'Normal' mode at the 'Exit via Test Mode / Normal Mode'
prompt.

In Purge
This routine is initiated at power up and after solution replacement
or an annual service.
ON
The analyzer has been taken off-line while the system is primed and
the reaction block temperature is stabilized. When the routine is
completed, the analyzer is ready for service.

In Recovery
The analyzer is in recovery mode.
This recovery routine introduces sample back into the system to
prepare it for return to run mode.

Pumps are Stopped

The pumps have been stopped manually.
All calibrations
OFF
If there is no problem with the wet section, switch the pumps back and cleans
on by pressing the key, highlighting 'Start / Stop Pumps' and
pressing the key.

Table B.1 Diagnostic Information, Relay Operations and Inhibits (Sheet 5 of 6)

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Multi-stream Appendix B – Diagnostics and Alarms

Out-of- Cal. in Cal.

Hold
Icon Diagnostic message Service Progress Failed Inhibits
Relay
Relay Relay Relay

Annual Service Due in 10 Days

Early warning that the next annual service is due in 10 days or less.

Annual Service Overdue*

Scheduled
The annual service is overdue.
calibrations
Carry out the next service immediately.

Less than x Days Reagent Left*

Early warning that reagent replacement is due in x days.
1. Set the alarm point to provide sufficient time for new reagents
to be ordered or prepared.
2. Clean the bottles before refilling them.

Out of All Samples

The analyzer cannot detect any sample or samples flowing into the
analyzer.
 If sample is lost for more than 15 minutes the analyzer shuts
down automatically.
 When sample is restored – if sample was lost for less than 15 All calibrations
OFF ON
minutes the analyzer continues measuring. and cleans

 When sample is restored – if sample was lost for up to 1 day

the analyzer restarts automatically with a recovery period.
 When sample is restored – if sample was lost for more than 1
day the analyzer starts an automatic chemical clean before
coming back on-line.

Out of Cleaning Solution

The cleaning solution bottle is empty.
1. Replace the cleaning solution. Scheduled
2. At the 'Calibration & Maintenance' level, select 'Solution cleans
Replacement' and at the 'Replace Cleaning Solution'
parameter, press the key to confirm that solution has
been replaced.

Out of Sample n
The sample indicated in stream 'n' is not present.
The indicated stream is excluded from the sampling sequence until
the analyzer has detected that sample has returned.

Out of Secondary Calibration Solution

The secondary calibration solution bottle is empty.
1. Replace the secondary calibration solution. Scheduled
secondary
2. At the 'Calibration & Maintenance' level, select 'Solution calibration
Replacement' and at the 'Replace Sec. Calibration Solution'
parameter, press the key to confirm that solution has
been replaced.

* Limits can be set – see Section 5.4.3, page 35

Table B.1 Diagnostic Information, Relay Operations and Inhibits (Sheet 6 of 6)

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Multi-stream Appendix B – Diagnostics and Alarms

B.2 Audit Log and Alarm Event Log

The 'Audit Log' and 'Alarm Event Log' are used to display a list of events and alarms identified by icon, sequence number, date and
time.
The 'Audit Log' provides an historical log of system activity, the 'Alarm Event Log' provides an historical log of all alarm events in the
sequence in which they occurred.
When the number of entries in each log has reached 500, the oldest data is overwritten by the newest data. Entries are renumbered
so that the number of the oldest entry is always 00.
Both logs are accessible from the chart view and bar view.

Note. Use the and keys to scroll through log data.

B.2.1 Audit Log – Icons B.2.2 Alarm Event Log – Icons

Icon Event Icon Event

Power failed Active high process alarm

Power restored Inactive high process alarm

Configuration changed Active low process alarm

File created Inactive low process alarm

File deleted Active high latch alarm

Archive media inserted Inactive high latch alarm

Archive media removed Active low latch alarm

Archive media off-line Inactive low latch alarm

Archive media on-line Active high annunciate alarm

Archive media full Inactive high annunciate alarm

System error / reset archiving Active low annunciate alarm

Date / time or daylight saving start / end changed Inactive low annunciate alarm

Security change Active clean-in-progress alarm

FTP logon Inactive clean-in-progress alarm

Information In sample alarm

Failure Out of sample alarm

Maintenance required Daylight saving start / end changed

Out of specification Alarm acknowledged

Check function Operator message

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Multi-stream Appendix C – Troubleshooting

Appendix C – Troubleshooting
C.1 Analyzer Malfunction C.2 Single-Stream Mode for Maintenance
For the analyzer to function correctly and to specification, the To carry out maintenance, switch to single-stream mode
following conditions must be met: (provided that a single stream is available) by disabling all
streams except one – see Section 5.4.1, page 34. If no streams
 The correct reagents and calibration solutions must be
are available, introduce a solution via the secondary calibration
connected.
valve.
 The order that the reagents are introduced into the
Single-stream mode stops multi-stream sequencing and
reaction block must be correct.
enables the display and the current output to respond with 3
 The flowrate of all solutions must be correct. minute updates to color changes in the cuvette. This mode is
 The analyzer's electronics (transmitter and optical used to check the basic performance of the analyzer, such as
measuring device) must be functioning correctly. response or drift, without waiting for the normal stream update.

Virtually all problems with the analyzer are as a result of 1 or

more of these not being correct. For troubleshooting it is
important to remember the basic analyzer functionality with
respect to the 4 conditions above.

C.3 Calibration Errors and Noisy or Incorrect Readings

Symptom Action

Failing calibration Check the system for visible air bubbles – see Section C.3.1, page 76
(calibration
Check that reagents enter the reaction block in the correct order – see Section C.3.3, page 78
parameters
consistent from one Check reagents are correct – see Section C.3.3, page 78
calibration to the Check solution flowrates – see Section C.3.3, page 78
next)
Check operation of zero and secondary calibration valves – see Section C.3.4, page 79
Check mV values from the optical system – see Section C.3.2, page 77

Failing calibration Perform a Noisy readings check – see below

(calibration
Check operation of zero and secondary calibration valves – see Section C.3.4, page 79
parameters vary from
one calibration to the Note. If a zero calibration is carried out on a sample with very high silica levels, the zero offset is
next) affected; this can result in low value samples reading zero or lower than expected.
Check mV values from the optical system – see Section C.3.2, page 77

Incorrect readings Check each stream reading independently. Switch off the sample flow to all streams except the one
(Calibrations pass being checked and remove the inlet tube from those constant head units, draining down the constant
with consistent head chamber. Measure each stream for at least 20 minutes or until stable readings are obtained. Ensure
results) the analyzer is configured for single stream operation – see Section C.2.
If readings are correct for individual streams but incorrect when the analyzer is running in multi-stream
mode, the problem is likely to be a leaking stream select valve. Replace the valve (see Appendix H,
page 88 – part number AW600034).
If all readings are the same as when run in full multistream mode:
1. Disconnect the cleaning solution tube from the clean valve manifold and check if the reading
changes after 30 minutes to 1 hour. If it does, the problem is likely to be a leaking clean valve.
Replace the valve (see Appendix H, page 88 – part number AW600034).
2. Disconnect the secondary calibration solution tube from the calibration valve manifold and check if
the reading changes after 30 minutes to 1 hour. If it does, the problem is likely to be a leaking
calibration valve. Replace the valve (see Appendix H, page 88 – part number AW600034).

If no problems can be found, it suggests that the laboratory method could be inaccurate.

Noisy / unstable Check the system for visible air bubbles – see Section C.3.1, page 76
readings
Check mV values from the optical system for stability – see Section C.3.2, page 77
Check solution flowrates – see Section C.3.3, page 78

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Multi-stream Appendix C – Troubleshooting

C.3.1 Air in System

Symptom Action

Air in system Check for air bubbles in the reaction block and in the tube feeding the optical unit.
If bubbles are found, check if they are present in the sample line or originate from one or more of the
reagents.
Note: Air can enter the system only from the suction side of the 2 pump assemblies.

1. From the sample line:

a. Check tube connections from the constant-head unit to the pump assembly, especially the
sample filter assembly – tighten if necessary.
b. Check the solenoid valves and ensure the screws on the reverse side are tight.

2. From the reagent line(s):

a. Check the pump tube connections.
b. Check the reagent bottle caps.

3. In the reaction block and tubing:

a. If bubbles in the reaction block and tubing are flowing smoothly, the problem is likely to be a
poor seal on one or more of the tube connectors.
b. Tighten tube connections as above. If the problem persists, replace the affected tubing
assembly – see Appendix H, page 87.

4. If bubbles are pulsing:

a. Check if there is a blockage or partial blockage. Blockages can be caused by overtight tube
connectors.
b. Check the tightness of all connectors in the sample or reagent line affected.

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Multi-stream Appendix C – Troubleshooting

C.3.2 Optical System Errors

Symptom Action

Unstable mV values The optical system receives mV signals from the cuvette and cuvette reference sensors. For accurate
readings both these values must be stable.
Note. When viewing these readings, be aware that if the silica level in the analyzer changes gradually,
the cuvette voltage also changes gradually.
To check mV values:
1. Press and select 'Diagnostic Information', 'Measurement Status'. The 'Measurement Status'
window is displayed and a mV signal value is displayed for the cuvette and the cuvette reference
sensors.
2. If the mV values are unstable and fluctuate by more than ± 10 mV over a short period of time, there
could be bubbles developing within the cuvette.
3. If bubbles are confirmed in the cuvette, check the tube connections – see Section C.3.1 above. If
the problem persists, perform a manual system clean – see Section 7.4, page 48.

Calibration failure or If there is no response or calibrations fail, check the output of the optical sensors as follows:
no response from
1. Empty the cuvette of reacted chemicals:
optical system
a. Press the key.
b. Select 'Calibration & Maintenance'.
c. Select 'Manual Test Settings'.
d. Select 'Test Pumps'.
e. Switch the reagent pump off and increase the speed of the sample pump to 5 rpm.
f. Run the sample pump at the increased speed for 5 minutes.
g. Set the sample pump speed back to its normal (previous) speed.

2. View the mV values in the 'Measurement Status' window.

3. If the optical unit is functioning correctly, the mV values are within the following ranges:
– Cuvette: 1000 to 2300 mV
– Cuvette Ref: 1000 to 2300 mV

4. If the Cuvette Ref signal is low, replace the optical unit (see Appendix H, page 88 – part number
AW601110).
5. If the Cuvette signal is low, perform a manual system clean – see Section 7.4, page 48. If the
problem persists, replace the optical unit (see Appendix H, page 88 – part number AW601110)

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Multi-stream Appendix C – Troubleshooting

C.3.3 Chemistry and Color Generation Errors

Symptom Action

Reagent order For correct chemistry and color generation to take place in the reaction block area, the reagents must
enter the reaction block in the correct order:
1. Check that each reagent is contained in the correct color-coded reagent bottle – see Fig. A.1,
page 67
2. Check that each reagent tube is inserted in the correct reagent bottle (see Fig. 3.1, page 9)

Chemistry and color For correct chemistry and color generation to take place in the reaction block area, the reagents must
generation errors flow correctly.
To check flowrates:
1. Remove all 4 reagent tubes from the reagent bottles.
2. Increase the reagent pump speed to 10 rpm – see Section 8.4, page 54.
3. Check the air / reagent interface is moving up each of the reagent tubes at the same rate. If one or
more is moving more slower than the others:
a. Check the pump capstan for damage.
b. Check the pump tube assembly is sealed correctly. If necessary, remove and refit the relevant
assembly, ensuring the O-rings are wetted.
c. Initiate a manual clean sequence to remove any possible partial blockages.

For correct chemistry and color generation to take place in the reaction block area, the reagents must
produce the correct color changes.
To quickly check that the reagents can produce the required color changes:
1. To 100 ml of a 1000 µgl-1 silica solution or even drinking water:
a. Add 10 ml of the first reagent (red channel – first acid)
b. Add 10 ml of the second reagent (violet channel – molybdate)

2. Wait 5 minutes and check that the yellow complex is formed.

3. Add 10 ml of the fourth reagent (brown channel – ascorbic acid)

4. Wait 5 minutes and check that the blue complex is formed.

Note. Reagent 3 is not used in this check as it is used to fine tune the chemistry in the analyzer for
accurate measurements

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Multi-stream Appendix C – Troubleshooting

C.3.4 Zero and Secondary Calibration Valve Malfunction

Check / Symptom Action

Secondary To check the valve:

calibration valve
1. Manually energize the secondary calibration valve – see Section 8.4, page 54 ('Manual Test
malfunction
Settings').
2. Check that the LED on the main board is lit and that there is an audible click from the solenoid
valve.

Zero calibration valve To check the valve:

malfunction
1. Loosen the sample filter assembly to allow air to be drawn into the system.
2. Check that in normal operation, the sample / air interface flows from the zero valve's common
(middle) port to the lower port.
3. When the sample / air interface has passed through the valve's lower port, manually energize the
valve and check that air flows out of the top port.
4. Tighten the sample filter housing and ensure that sample flow is restored.
5. When sample flows from the valve's top port, manually de-energize the valve and check that
sample flows out of the lower port.

Zero Valve

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Multi-stream Appendix D – Online Help

Appendix D – Online Help

Fig. D.1 Context-sensitive Help

If any alarms or messages appear on the operator screen, press

the key to open the help at the relevant help topic.
The help goes directly to the relevant topic when selected from
any menu item. For example, if the 'Language' field is
highlighted and the help is opened, the help opens at the
language topic.
1. Press the key, use the and keys to select 'Help'
and press the key.
2. Highlight a section icon ( ). If it changes to an icon,
there are help topics ( ) available – press the key to
open it.
If the section icon remains closed, the section it represents
contains sub-sections and files. Press the key to open
the section and reveal the sub-sections. Repeat the
process for sub-sections. Press the key to close a
sub-section or section.
3. Press the key to view the selected help file and use the
and keys to scroll through it.
4. To exit the on-line help, press the key repeatedly to
return to the screen from where help was first selected.

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Multi-stream Appendix E – Web Server

Appendix E – Web Server

Fig. E.1 Web Server Screen

The analyzer is fitted with an ethernet card as standard and, d Language Selection – selects the language for the web
when the appropriate configuration settings have been made, pages.
users can access the analyzer's data via an Ethernet network.
e Auto-Refresh – updates the analyzer view automatically.
In addition, files can be transferred to and from the analyzer via
f View Selection – selects the required analyzer view:
an FTP connection.
– Alarm / Event Log
a Log On – click to log on to the analyzer to enable
configuration access. – Audit Log
b Analyzer View – displays the current screen of the – Chart View
analyzer. If the analyzer has a screen-saver set, it does not – Bar View
affect this view.
c Access Buttons – provides access to the analyzer's data
if the user has the appropriate access permission.
– Stream Values – see Appendix E.1, page 82.
– Reagent & Solution Levels – see Appendix E.2,
page 82
– Measurement Status – see Appendix E.3, page 82
– Valve & Pump Status – see Appendix E.4, page 82
– Statistics – see Appendix E.5, page 82
– System Information – see Appendix E.6, page 82
– Logging Status – see Appendix E.7, page 82
– Operator Messages – see Section E.8, page 83
– Configuration – see Appendix E.9, page 83

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E.1 Stream Values E.5 Statistics

E.6 System Information

E.2 Reagent & Solution Levels

E.3 Measurement Status E.7 Logging Status

E.4 Valve & Pump Status

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E.8 Operator Messages E.9 Configuration

Change or retain
security configuration

Select a configuration previously

saved to internal storage or select
a QuickStart template

Change the analyzer's current date

and time

An 'Operator Message' is displayed on the chart view. For Note. A user must be logged-on for the configuration
example: button to be enabled.

E.10 FTP Access

Files can be transferred between the analyzer and a remote
computer via an FTP connection if the analyzer has been
An entry is also included in the 'Alarm Event Log'. configured with the appropriate settings – see Section 5.8.1,
page 41.
An Instruction is displayed on the analyzer as a warning, for
example: Either Microsoft® Internet Explorer version 5.5 (or later) or
MS-DOS® can be used as an FTP client.

Operator instructions can be removed only by pressing the

key.
To send an operator message or instruction to the analyzer:
1. Type the 'User name' and 'Password'. Up to 160
characters can be used. These are the FTP username and
password that are set in the configuration – see
Section 5.8.1, page 41.
2. Type either the message or an instruction (only one field
can be populated at any one time).
3. Click the button to send the message or instruction
to the analyzer.

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Multi-stream Appendix E – Web Server

E.11 FTP Access via Internet Explorer

3. Type the 'User name' and 'Password' and press enter.
Note. FTP access requires Internet Explorer version 5.5 or The folders that are present on the analyzer are displayed.
later.
4. Open the folder containing the file to be displayed. The
files within the folder can be displayed in any standard
Before data can be accessed via FTP, Internet Explorer must be Explorer view (small icon, large icon, list or details) by
configured with the appropriate options. selecting the appropriate option from the 'Views' menu.
To ensure that the latest data file is copied, Internet Explorer
must be set to check for newer versions of stored pages on Note. The SDMMC folder is visible only if an SD card
every visit to a page. Internet Explorer must also be set to is present and logging is set to 'On-line' – see
enable FTP access. Section 9, page 55.
To configure Internet Explorer:
5. Files / Folders can be copied to / from the analyzer.
1. From the Internet Explorer 'Tools' menu select 'Internet
Options'.
2. In the 'General' tab of the displayed dialog box, click the Note. An audit log entry is created and displayed for
'Settings' button in the 'Temporary Internet Files' each FTP logon giving details of the logon user name
grouping. and access (full or read-only). When Internet Explorer
is used as the FTP client, two log-ons are performed
3. From the options for 'Check for newer versions of stored at the start of each session resulting in two log entries.
pages:', select 'Every visit to the page' and click 'OK'.
4. Select the 'Advanced' tab of the 'Internet Options' dialog E.12 FTP Access via DataManager
box, ensure that the 'Enable folder view for FTP sites DataManager can be used with FTP to access data files that
option' under the 'Browsing' heading is selected and click have been saved to the archive media (SD card) inserted in the
'OK'. analyzer. For DataManager configuration details for FTP access,
refer to the DataManager User Guide, IM/DATMGR.
To access data stored on the analyzer via Internet Explorer:
1. Start Internet Explorer. E.13 File Transfer Program
A File Transfer Scheduler Program (FTSP) is available that
2. In the 'Address' bar, enter 'ftp://' followed by the IP enables archive and configuration files to be transferred
address of the analyzer from which the files are to be automatically to a PC using FTP. The transferred files can be
copied. A log-in dialog box is displayed: stored either on the local drive of the PC or on a network drive
for easy access and secure back-up.
To download the FTSP program (FTS.exe), enter the following
(without spaces) in your web browser's Address bar:
http://search.abb.com/library/ABBLibrary.asp?DocumentID=FT
S.exe&LanguageCode=en&DocumentPartId=&Action=Launch
To download the FTSP User Guide (IM/SMFTS), enter the
following (without spaces) in a web browser's address bar:
http://search.abb.com/library/ABBLibrary.asp?DocumentID=IM/
SMFTS&LanguageCode=en&DocumentPartId=&Action=Launc
h

84 IM/NAV6S/MS–EN Rev. D
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Multi-stream Appendix F – Updating the Software

Appendix F – Updating the Software

7. A 'Warning' screen appears next. This provides the option
to upgrade the existing system software, or exit without
upgrading:
Normal
Operation (Up)
Software
Update
(Down)
C
B
A

8. To proceed, press the key.

9. The 'Commissioning V2.0' screen appears with the
Fig. F.1 SD Card Removal
'Upgrade Firmware' button selected:

1. Unzip the upgrade software file and copy the contents of

the folder created to an SD card.

Note. Use only genuine SanDisk SD cards with a

capacity of 2 Gb or less.

2. Ensure the analyzer is switched off.

3. Use a large flat-headed screwdriver to release the two
door catches A.
4. Remove the SD card B.
5. Set the switch C (above the SD card socket) to the lower
position (Software Update).
6. Insert the SD card, close the door and switch on the
analyzer. A start-up message is displayed for
approximately 5 seconds, followed by an 'ABB' splash 10. To upgrade the existing system software, press the
screen: key to start the process. (The software is transferred to the
analyzer in sections.)
11. Press the key as each section is installed (installation
may take a few moments).
12. Open the door and move the switch to the up position.
13. Close the door.
14. Turn power off and then on to restart the analyzer.

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Multi-stream Appendix G – Analyzing a Grab Sample

Appendix G –
Analyzing a Grab Sample
To analyze a grab sample:
1. Disable all streams apart from one:
a. at the 'Main Configuration' menu, select 'Measurement'
and scroll down to 'Enable Streams'.
b. press 'Enter' and untick each stream, leaving 1 ticked.
c. press the 'Menu' key and exit by 'Saving Current
Configuration' to internal memory.

2. Setup a grab sample:

a. unscrew the Secondary bottle lid and remove the level
sensor.
b. rinse the level sensor with high purity water.
c. place the level sensor into a grab sample container.

3. Energize the Secondary Calibration Valve:

a. at the 'Calibration & Maintenance' parameter, select
'Manual Test Settings' and press 'OK' (this takes the
unit Offline).
b. go to 'Test Valves' and set 'Sec. Cal Value On' by
pressing Enter.
c. exit this section by selecting 'TEST' mode (not
'NORMAL').

4. Measure the sample:

a. leave the sample flowing for at least 20 minutes – the
reading stabilizes between 15 and 20 minutes,
depending upon the difference in silica levels from the
analyzer sample and the grab sample.

5. Finish:
a. remove the level sensor form the grab sample, rinse
thoroughly with high purity water, place back in the
secondary calibration solution.
b. leave running for a 5 minutes to allow the sample line
to flush through.

6. Enable all the streams to be sample as before – follow

step 1,ensuring all required streams are ticked.
7. De-energize the Secondary Calibration Valve:
a. return to the 'Calibration & Maintenance' parameter
'Manual Test Settings' option, select 'Exit' and press
'Enter'.
b. exit this section by selecting 'NORMAL' (not 'TEST') –
the analyzer now reverts to normal operation following
a recovery period.

86 IM/NAV6S/MS–EN Rev. D
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Multi-stream Appendix H – Spare Parts

Appendix H – Spare Parts

Warning.
Spares items identified with the symbol must be fitted only by ABB personnel or an ABB-approved representative.

Part No. Description Part No. Description

AW601155 Annual spares kit (suitable for analyzers with AW600097 Pump tube grey
upgraded pumps and instruments manufactured (see AW601108 and AW602108)
after October 2010)

AW601108 Pump tube kit containing AW600096,

AW600097, AW601118 & AW601119

AW601176 Tubing kit (excluding pump tubes)

AW601102 Reagent tubes replacement kit

AW600096 Pump tube blue & green (see AW601108 and

AW602108)
AW600049 Filter assembly

AW600087 Filter pack

AW601118 Pump tube red & violet (see AW601108)

AW600503 2-channel pump pressure plate

(only for upgraded units)

AW601119 Pump tube orange & brown (see AW601108)

IM/NAV6S/MS–EN Rev. D 87
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Multi-stream Appendix H – Spare Parts

Part No. Description Part No. Description

AW600047 Pump motor and coupling AW600034 Calibration / clean / cuvette / sample select valve
incl. manifold

AW600710 Out of sample switch new type AW600046 Reaction block temperature sensor

AW600045 Reaction block heater

AW600726 Float switch level sensor – grey

AW601110 Optical unit (excluding secondary debubbler)

AW600701 Constant head assembly multi stream – left-hand

side end and mid module
AW600727 Float switch level sensor – yellow

AW600705 Constant head assy multi stream – right-hand

side end module

AW600025 Primary debubbler

Blanking plug

88 IM/NAV6S/MS–EN Rev. D
Navigator 600 Silica
Multi-stream Appendix H – Spare Parts

Part No. Description Part No. Description

AW601181 Reaction coil, manifold & cover AW600023 Cable gland kit

AW600730 Bottle empty – cleaning solution / secondary

calibration / zero calibration

AW600048 Wet section connection PCB

AW600731 Bottle empty – reduction ascorbic / ammonium

molybdate / 1st acid / 2nd acid
AW600051 AC power supply

AW600056 DC power supply

AW600085 Wet section door & hinge pins

AW600065 Transmitter application board

AW600067 PROFIBUS board

AW600157 Reagent shelf

IM/NAV6S/MS–EN Rev. D 89
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Multi-stream Appendix H – Spare Parts

Part No. Description

AW600028 AC Transmitter (excluding PROFIBUS card)

AW600016 DC Transmitter (excluding PROFIBUS card)

AW600068 Front door inc. keypad and display

AW601175 Complete wet section multi-stream tested

AW601715 Secondary debbubler assembly

AW601720 Pre-heater assembly

90 IM/NAV6S/MS–EN Rev. D
Navigator 600 Silica
Multi-stream Index

Index
A I
Access Illustrated spares list ....................................................... 87
User access .............................................................. 32 Inactive user disabling ..................................................... 31
Accessories .................................................................... 15 Installation ...................................................................... 15
Alarms Location .................................................................... 16
Fail safe ..................................................................... 37 Instrument diagnostic information ................................... 68
Relay contact protection ............................................ 23 Instrument tag ................................................................ 28
Relays ....................................................................... 36 Interference suppression ................................................. 23
Annotation
Chart ......................................................................... 60 L
Archive Language ....................................................................... 28
Configuration ............................................................. 40 Logging
File types ................................................................... 58 Configuration ............................................................ 39
Automatic chemical cleaning ........................................... 47
Automatic shutdown ....................................................... 14 M
Maintenance ................................................................... 50
B Calibration ................................................................ 45
Brightness ....................................................................... 28 Cleaning ................................................................... 47
Sample filter replacement .......................................... 53
C Scheduled ................................................................ 50
Cable connections .......................................................... 22 Measurement status ....................................................... 62
Chart Messages ....................................................................... 33
Annotation ................................................................. 60 Operator ................................................................... 60
Functions .................................................................. 60 Minimum password length .............................................. 31
Chemical solutions .......................................................... 50 Mounting ........................................................................ 18
Cleaning Multi-stream operation .................................................... 12
Automatic chemical cleaning ..................................... 47
Cleaning solution ....................................................... 67 N
Setup ........................................................................ 48 Navigation ...................................................................... 25
Communications ............................................................. 41
Connections O
Cable connections ..................................................... 22
External electrical connections ................................... 20 Operation – Calibration and maintenance ....................... 45
Operator
Controls .......................................................................... 25 Messages ................................................................. 60
Current outputs ............................................................... 38
Passwords ................................................................ 31
Security .................................................................... 31
D
Outputs .......................................................................... 38
Date and time ................................................................. 29
Daylight saving .......................................................... 29, 59
Diagnostic information ..................................................... 68 P
Dimensions ..................................................................... 18 Password expiry ............................................................. 31
Display Password failure limit ...................................................... 31
Brightness ................................................................. 28 Passwords ............................................................... 30, 32
Pumps status ................................................................. 63
E
R
Editing ............................................................................. 25
Email ............................................................................... 42 Reagent levels ................................................................ 62
Ethernet .......................................................................... 41 Reconfigure preset ......................................................... 31
Recording ....................................................................... 39
Relays ............................................................................ 36
F Contact protection and interference suppression ...... 23
Fail safe ........................................................................... 37
File viewer ....................................................................... 57
Filters .............................................................................. 53
Flow schematic ................................................................. 8
Front panel controls ........................................................ 25

H
Historical review .............................................................. 60
Hysteresis ....................................................................... 37

IM/NAV6S/MS–EN Rev. D 91
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Multi-stream Index

S
Sample filter replacement ................................................53
Sampling requirements ....................................................16
Schematic .........................................................................8
Screen capture ................................................................28
Screen interval .................................................................60
Screen saver wait time ....................................................28
SD Card ..........................................................................56
Security ...........................................................................30
Security type ...................................................................31
Shutdown
Automatic ..................................................................14
Software
Updating ....................................................................85
Solution levels .................................................................62
Solutions ...................................................................50, 66
Spares
Illustrated spares list ..................................................87
Statistics .........................................................................63
Status
Measurement .............................................................62
Valves and pumps .....................................................63
System information ..........................................................62

T
Time ................................................................................29
Troubleshooting ..............................................................75
Tubing
Schematic ...................................................................8

U
Unpacking .......................................................................15
Updating the software .....................................................85
User settings ...................................................................32

V
Valve status .....................................................................63

W
Web server ......................................................................81

92 IM/NAV6S/MS–EN Rev. D
Products and customer support
Automation Systems Customer support
For the following industries: We provide a comprehensive after sales service via a
— Chemical & Pharmaceutical Worldwide Service Organization. Contact one of the following
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Sensors
— Ammonia, Nitrate, Phosphate, Silica, Sodium, Chloride,
Fluoride, Dissolved Oxygen and Hydrazine Analyzers Client Warranty
— Zirconia Oxygen Analyzers, Katharometers, Hydrogen Prior to installation, the equipment referred to in this
Purity and Purge-gas Monitors, Thermal Conductivity manual must be stored in a clean, dry environment, in
accordance with the Company's published specification.
Periodic checks must be made on the equipment's
condition. In the event of a failure under warranty, the
following documentation must be provided as
substantiation:
— A listing evidencing process operation and alarm logs
at time of failure.
— Copies of all storage, installation, operating and
maintenance records relating to the alleged faulty unit.
Contact us

ABB Limited

09.2012
Note
Process Automation We reserve the right to make technical changes or
modify the contents of this document without prior
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IM/NAV6S/MS–EN Rev. D
notice. With regard to purchase orders, the agreed
Stonehouse particulars shall prevail. ABB does not accept any
Gloucestershire GL10 3TA responsibility whatsoever for potential errors or
UK possible lack of information in this document.

Tel: +44 1453 826 661

We reserve all rights in this document and in the
Fax: +44 1453 829 671 subject matter and illustrations contained therein.
Any reproduction, disclosure to third parties or
utilization of its contents in whole or in parts – is
forbidden without prior written consent of ABB.
ABB Inc.
Process Automation Copyright© 2012 ABB
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Internet Explorer™ are registered trademarks of
Tel: +1 215 674 6000
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