ABB LevelMaster 7100 User Manual Download

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Accurate and reliable
measurement of storage tank
liquid level for custody transfer
and tank level management
applications

User manual

Liquid level sensor with batteryless float support

LevelMaster 7100

Summary of Contents for LevelMaster 7100

Page 1: ...Accurate and reliable measurement of storage tank liquid level for custody transfer and tank level management applications User manual Liquid level sensor with batteryless float support LevelMaster 7100 ...

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Page 3: ...pecifications 4 LevelMaster components 4 Software interfaces 6 Installation scenarios 7 3 Installation 10 Site planning and requirements 10 Unpack and inspect 11 Assembly 15 Install or set the position of the high level auxiliary switch optional 17 Insert the unit into the tank 19 4 Wiring 22 Board versions overview 22 Selecting wire type 24 Wiring the first LevelMaster 24 Wiring additional LevelM...

Page 4: ... collection 56 Save the configuration 59 Duty cycling power optional 60 Push to Read optional 61 7 Calibration from the host controller 62 Calibration for level measurement level bias 62 Calibration for volume calculations 63 8 Service and maintenance 65 Remove the enclosure cover 65 Remove field wiring 66 Restore field wiring 67 Remove the unit from the tank 67 Reinstall the unit into the tank 68...

Page 5: ...ce the sensor assembly 78 Move a LevelMaster from one tank to another 80 9 Troubleshooting 81 Appendix A Tank level pass through 86 A 1 LevelMaster protocol commands 86 A 2 Activating the tank level pass through 87 Contact us 90 ...

Page 6: ...ral schematic of a multi LevelMaster bus general purpose location 27 Figure 24 Two LevelMaster RS 485 bus of same board type using both communication contact pairs 29 Figure 25 Three LevelMaster RS 485 bus same board type 29 Figure 26 Two LevelMaster RS 485 bus of same board type using single communication contact pair 30 Figure 27 Two LevelMaster RS 485 bus mixed board type 30 Figure 28 LevelMast...

Page 7: ... Locating the correct factory default configuration file 75 Figure 63 LevelMaster Upload Download tab 75 Figure 64 LevelMaster Setup tab for ID and Baud rate configuration 76 Figure 65 Inserting new floats 77 List of tables Table 1 General LevelMaster specifications 4 Table 2 LevelMaster parts list 13 Table 3 LevelMaster optional parts list 13 Table 4 Cables and adapters for direct connection to t...

Page 8: ...o to section 2 1 Device setup Greater than character Indicates that the following item is an additional menu selection Use the key pad to locate and select Calibrate Diff Press Sensor Calibration Units Edit Programs including utility and accessory programs Title capitalization Microsoft Word URL All lowercase for a fully specified URL If necessary break long URLs before a forward slash or break a ...

Page 9: ...teryless float support 2105824 XRC XFC connected to LevelMaster 2105833 RMC connected to LevelMaster 2105831 RMC and serial converter connected to LevelMaster 2105832 Software MasterLink software version 2 0 software 2100197 005 Documents and user drawings for board with part number 2018546 005 legacy board LevelMaster startup guide 2103656 LevelMaster user manual 2018374 LevelMaster 2018546 BD W ...

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Page 11: ...he text may state the hazard how to avoid the hazard and what the result would be if not followed DANGER Serious damage to health risk to life This symbol in conjunction with the signal word DANGER indicates an imminent electrical hazard Failure to observe this safety information will result in death or severe injury The text may state the hazard how to avoid the hazard and what the result would b...

Page 12: ...truction on the use operation and maintenance of devices with electrical circuits in general purpose locations and possibly in classified hazardous locations Follow relevant national and local electrical code requirements and the certification installation drawing listed on the name plate shipped with the sensor Removal of the enclosure cover in a hazardous location must follow guidelines stipulat...

Page 13: ...ABB Totalflow host controllers remote controllers or flow computers a wide range of data gathering and site automation applications are available Figure 1 Typical LevelMaster oil and water tank installation The LevelMaster consists of a sensor that sits on the bottom and extends through the top of a vessel A reducer bushing and compression fitting can be provided for tanks with standard 3 inch or ...

Page 14: ... at 68 F 0 47 Water float specific gravity at 68 F 0 91 Emulsion float specific gravity at 68 F 0 75 Materials and dimensions Casing material Fiberglass or stainless steel pressurized tanks Casing outer diameter 1 95 inches 48 5 mm Float outer diameter 3 17 inches 80 5 mm 2 85 inch single float on request Reducer bushing and compression fitting Fits standard 3 and 4 inch 10 16 mm tank port Tempera...

Page 15: ...ard type there may be a single connector handling both power and communications or two separate connectors for each The ports have terminal connectors that are removable for convenient field wiring IMPORTANT NOTE Access to the onboard ports for wiring or local connection requires removal of the enclosure cover Sensor port An onboard 16 pin port provides the connection point for the sensor assembly...

Page 16: ...or hardware replacement and if the existing configuration file is not available a file for the appropriate length can be located in the MasterLink folders and used to update the unit MasterLink version 2 0 is required for support of batteryless floats and for LevelMasters with board part number 2104836 MasterLink is used to accomplish the following Basic configuration Configuration of unit ID Conf...

Page 17: ...ionality as PCCU Collection of the LevelMaster data stored in the flow computer or remote controller is also supported from WinCCU and other ABB Totalflow software applications Installation scenarios The LevelMaster can be installed in several different field configurations The choice of configuration depends on the site requirements measurement data gathering requirements and the level of automat...

Page 18: ...er or from an external power supply If using an external power supply connection must also be done through the barrrier HOST CONTROLLER BARRIER BOARD NON HAZARDOUS AREA HAZARDOUS AREA CLASS I DIV 1 GROUP D RS 485 VDC PWR RS 485 VDC PWR RS 485 VDC PWR LAST SENSOR ON RS 485 BUS MUST BE TERMINATED FIRST OR INTERMEDIATE SENSOR ON RS 485 BUS NOT TERMINATED Figure 3 LevelMaster configuration example for...

Page 19: ...LevelMaster 7100 User manual 2105835 Rev AA 9 Figure 4 Installation with high level auxiliary switch 12 inch option ...

Page 20: ...t controller remote controller or flow computers is beyond the scope of this manual Only pertinent details to their interface and communication configuration with the LevelMaster are included in this manual Refer to the user manual and the help files in PCCU32 for details If using third party control equipment consult their respective user manuals General planning Before installing the LevelMaster...

Page 21: ...f 500 feet Class 1 Division 1 Group C D when connected through Totalflow CSA certified barrier boards One barrier board supports up to three level sensors with a maximum distance of 500 feet IMPORTANT NOTE Figure 5 shows the barrier enclosure not the actual barrier board The barrier board required depends on the location classification Two board options are available for Class 1 Division 1 locatio...

Page 22: ...y ABB Damaged components If any components have been damaged or if there are noticeable defects notify an ABB representative Keep all shipping materials for the carrier s inspection ABB will arrange for immediate repair or replacement see the Contact us section located on the last page of this manual Parts list Figure 6 depicts each component of the fully assembled LevelMaster as required for inst...

Page 23: ...nch pipe nipple located between the top cap bushing and the electronics enclosure None 1 or 2 Float 1 2 or 3 inch diameter Number is different for each type of float Float types passive or active inlcuding batteryless Liquid type Oil or water Two floats are required for an oil and water application 2018392 017 Batteryless float kit requires board with part number 2104836 001 Oil level float part n...

Page 24: ...es the choice of the cables and adapters depends on the board part number Verify that the correct cable and adapter are available for the installation IMPORTANT NOTE Variations of cable types with other part numbers may be available Contact ABB if the list provided in Table 4 does not meet the site requirements Table 4 Cables and adapters for direct connection to the LevelMaster Board Description ...

Page 25: ...nd adapter required for connection to board part number 2018546 005 Cable Adapter P N 2100250 001 RS 232 RS 485 converter P N 2100241 002 9V Batt 9V Batt Connect to Computer 1 Serial or 2 USB using additional adapter Note Disconnect the red wire connector from battery holder when cable is not in use Failure to do so will result in a constant battery drain Connect to Level Master board P N 2018546 ...

Page 26: ...other sealing material on the tank port bushing threads 4 Slide the cord connector and bushing into the bottom of the LevelMaster with the cord connector on top Figure 9 The nut on the cord connector may need to be losened so it slides freely on the casing TANK PORT BUSHING NUT TOP OF LEVELMASTER CORD CONNECTOR Figure 9 Cord connector and tank port bushing installation 5 Slide the float s onto the...

Page 27: ...t into the tank Install or set the position of the high level auxiliary switch optional The following sets the position of the high level auxiliary switch IMPORTANT NOTE The LevelMaster is typically shipped with the auxiliary switch assembly already installed in the 4 inch tank port bushing The following procedure describes how to position the float for the desired operation If purchased separatel...

Page 28: ... character inscription above the center of the float Figure 14 The inscription should be in the upright position it can be read when the LevelMaster is in the vertical position It will read either NO or NC Figure 14 displays NO If it is not in the desired position a Pull the retainer clip off b Turn the float over c Re install the float switch d Place the retainer clip back into place Figure 14 Au...

Page 29: ...s There are two wires coming from the switch representing the two sides of the switch There are no polarity considerations 4 Proceed to section 3 5 Insert the unit into the tank Insert the unit into the tank The following installation assumes the LevelMaster is being installed through a standard 3 inch or 4 inch tank port opening and that all components have been assembled including the high level...

Page 30: ...o resistance 3 Raise the LevelMaster vertically 4 Ensuring that the float s are still all the way at the bottom of the casing lift the unit and move to the top of the tank 5 Once on top of the tank carefully feed the casing and float s through the tank port opening 6 Slowly lower the LevelMaster assembly and allow the unit s weight to keep the unit vertical If the bottom of the tank has sludge the...

Page 31: ... Tighten the nut of the cord connector to form a rain tight seal around the casing 12 Plumb the conduit or cable for the wiring into the inch hub on the side of the electronics enclosure a For division 1 and 2 hazardous areas use a conduit b For general purpose areas a cable with a cord connector can be used 13 Proceed to section 4 Wiring ...

Page 32: ... used to make a connection between the person handling the board and a high quality ground point Before handling the board install a ground strap on the body and then connect it to a grounded point This discharges electrical static buildup from the body to ground preventing static from discharging to the electronics Board versions overview Wiring and configuration of the LevelMaster vary depending...

Page 33: ... when lit Onboard termination jumpers legacy boards only For electronics boards part number 2018546 005 only onboard jumpers JP1 in Figure 20 provide a way to configure the LevelMaster for connection to additional LevelMasters on an RS 485 bus Figure 20 shows the placement of the JP1 jumpers depending on the position of the LevelMaster on the bus Figure 20 RS 485 termination for legacy board part ...

Page 34: ... limits defined for the wire conductor s cross section area based on whether stranded or solid wires are used Wiring the first LevelMaster Wiring requires wire termination at both the LevelMaster and the host controller or additional units The procedures in this section describe the wiring at the first LevelMaster end The first LevelMaster on an RS 485 bus is the unit that connects to the host con...

Page 35: ...RS 485 bus ensure that it is configured as an intermediate sensor factory default For legacy boards part number 2018546 005 terminate as described in section 4 1 3 Onboard termination jumpers legacy boards only a If the unit is the only unit connected to the flow computer or remote controller insert the wires run from the host controller in one of the pin pairs available first and fourth pin or se...

Page 36: ...ate power source in the positions Secure the inserted wires by tightening the screws on the connector b If the unit is an intermediate unit on the bus additional units will be connected i Insert the wires for power run from the host controller or alternate power source in the positions and leave screws loose to insert the wires from an additional LevelMaster ii Insert the wires for power run from ...

Page 37: ... with host controller Direct connection to host controller No barrier required 4000 8 Hazardous location classified area with host controller No direct connection to host controller CSA certified barrier required between first LevelMaster on the bus and host controller 500 Group D 4 sensors per barrier Group C D 3 sensors per barrier Wiring for communication To wire the additional LevelMaster s fo...

Page 38: ...Master in the power positions Secure the wires by tightening the screws for each terminal position wired b If the additional LevelMaster is an intermediate unit on the bus additional units will be connected i Insert power wires from the first LevelMaster in the positions and leave screews loosen to insert the wires from the next LevelMaster ii Insert power wires from the next LevelMaster in the po...

Page 39: ...tions depend on the type of wire gauge and user preference see section 4 2 Selecting wire type Figure 26 shows a two LevelMaster bus with boards of the same type where the communication connection for the additional LevelMaster is through the same connection pair on the RS 485 port on the first LevelMaster instead of using both pairs as in shown in Figure 24 While using both pairs is recommended t...

Page 40: ...rs are placed on 5 6 7 8 and 9 10 as indicated in section 4 1 3 Onboard termination jumpers legacy boards only 2 1 JP1 J1 V V T T D9 J12 1 3 J11 POWER EARTH T T T T R R Legacy electronic board 2018546 005 New electronic board 2104836 001 Intermediate sensor on RS485 bus Last sensor on RS485 bus Bus Bus GND PWR To host controller and power source 1 Direct connection or 2 Through barrier Figure 27 T...

Page 41: ...plied from one of the host controller serial COM ports IMPORTANT NOTES Determine which COM port is available for wiring on the host controller Some ABB Totalflow devices have COM1 pre configured and reserved for remote communications COM ports on Totalflow flow computers or remote controllers must be configured as RS 485 ports to support the connection with the LevelMaster Ensure that legacy RS 48...

Page 42: ...etails specific to the flow computer or remote controller being wired Figure 29 shows how to wire the LevelMaster to either of the onboard COMM ports available on the XRC or XFC Any port can be selected as long as the communication module for RS 485 is installed LEVEL MASTER XFCG4 XFC 6400 COMM 1 XRCG4 XRC COMM 1 or 2 XFCG4 XFC 6400 COMM 2 J11 J4 J4 J6 6 4 1 2 13 12 1 2 6 8 2 1 RMC 100 COMM 1 or 2...

Page 43: ...COMM 2 COMM 1 21 3 1 T GND 12 VDC T J4 2 12 VDC GND J4 6 TX J4 4 TX 4 16 15 8 7 13 14 12 6 5 J4 11 10 3 2 9 1 COMM 1 J4 13 TX J4 12 TX 4 16 15 8 7 13 14 12 6 5 J4 11 10 3 2 9 1 COMM 2 J4 2 12 VDC GND J6 9 8 7 6 5 4 1 2 3 3 9 8 7 6 5 4 1 2 J6 1 12 VDC BLK J6 2 GND WHT J6 6 TX BRN J6 8 TX RED COMM 1 J6 9 8 7 6 5 4 1 2 3 3 9 8 7 6 5 4 1 2 J6 1 12 VDC BLK J6 2 GND WHT J6 6 TX BRN J6 8 TX RED COMM 2 XF...

Page 44: ...the power source for the RMC must be 12 VDC For a COMM port to be activated the COMM module Part 2105236 001 must be in the slot for the appropriate COMM port The module is software selectable for communication protocol type This includes the Pin 1 VOUT RMC 2105350 Board INP GND INP GND 1 2 3 4 5 6 7 8 9 COMM 1 COMM 2 BAT CHARGER EXT PWR PI 1 2 RMCIO EXPANSION COMM 1 COMM 2 WARNING DO NOT SEPARATE...

Page 45: ...rrier boards Hazardous area certification restrictions limit the number of LevelMasters and the length of cable that can be fed through the barrier Those limitations are described in Table 6 Table 6 Wiring limitations when using barrier boards Installation scenario Barrier board part number Number of barriers Maximum wire length in feet from barrier to LevelMaster Maximum number of LevelMasters on...

Page 46: ... back on the barrier board 6 Proceed to section 4 5 2 3 Wiring the barrier board to the host controller Wiring the barrier board to the host controller This procedure wires the barrier board to the host controller to complete end to end wiring in the hazardous location To wire the barrier board to the host controller 1 Remove the J1 and J4 terminal connectors 2 Loosen the screws on the J1 and J4 t...

Page 47: ...d located below the power connector is not lit If it is lit it indicates that the wrong polarity has been used and it must be rewired to correct polarity 4 Verify that the power LED does not light in additional LevelMasters that may be connected 5 When verification of wiring is complete remove the power connector from the LevelMaster electronic board and proceed to ground section 4 7 or configure ...

Page 48: ...LevelMaster 7100 User manual 2105835 Rev AA 38 Figure 35 Grounding the electronics board ...

Page 49: ... the previous version and therefore there could be two separate instances of MasterLink in the same laptop The new instance will not have any existing configuration files because they are not automatically available in the new installation directory To continue managing all the installed LevelMasters with MasterLink 2 0 configuration files may be copied to the new installation directory To install...

Page 50: ...replicated in this section for convenience The converter cables adapters and USB adapters must be all be connected to be able to attach the laptop to the LevelMaster The cables and adapters described in this section are included as examples Additional cable lengths and variations are available for purchase from ABB To assemble the cable and adapters for connection 1 Connect the RS 485 to RS 232 co...

Page 51: ...esponding ports on the board b Plug the RS 232 to RS 485 converter to the USB converter if using the laptop USB port c Plug the USB converter to the USB port on the laptop Figure 38 Connecting the laptop to the electronics board IMPORTANT NOTES For boards part number 2018546 005 legacy boards the MasteLink cable will not operate with the fourth jumper installed JP1 pins 7 and 8 jumpered on the onl...

Page 52: ...t of location and unit names This information is automatically retained in a location file created by the software Several location files can be created to reflect different customer sites if needed to keep them separate Locations and units are displayed by the MasterLink main screen in tree view format to ease unit selection for configuration or monitoring The procedure included in this section a...

Page 53: ...tup 7 Select I have only one LevelMaster connected to communication port and I want to set it up 8 Click Setup LevelMaster 9 When prompted to add the LevelMaster to the list click Yes 10 When prompted for the LevelMaster name type up to 15 characters and click OK The name will be stored in the location file and associated with the newly created location 11 Observe the messages displayed on the mon...

Page 54: ...igure 42 MasterLink Setup tab 13 In the New LevelMaster ID field type a number from 1 to 99 for the ID Take note of the ID used and ensure it is not used for any of the other LevelMasters on the site if all are connected on a common RS 485 bus Each ID on the bus must be unique for communication to succeed ...

Page 55: ...to calibrate the unit or add level bias in section 5 3 3 Calibration standalone installations only b If the LevelMaster is the only unit installed or it is the last unit on an RS 485 bus proceed to section 5 3 2 Configuring RS 485 bus termination Configuring RS 485 bus termination Use this procedure in order to eliminate signal echo if the LevelMaster is the only unit or the last unit on an RS 485...

Page 56: ...it is not connected to an ABB Totalflow host controller proceed to calibrate the unit or add level bias in section 5 3 3 Calibration standalone installations only next Calibration standalone installations only Although the LevelMaster is a highly accurate factory calibrated device there can be subtle discrepancies that may require the floats to be calibrated in the field For example discrepancies ...

Page 57: ... only Perform this procedure only if the calibration was done through MasterLink as described in section 5 3 3 Calibration standalone installations only above IMPORTANT NOTE Verification of calibration consists of verifying that the actual level readings of the LevelMaster once inserted in the tank agree with the tank levels inserted manually Follow the steps below once the electronics board is in...

Page 58: ...ration is completed and saved and calibration if performed is verified ensure that the field wiring connections are restored IMPORTANT NOTE If the electronics boards are removed for configuration final verification of communication on the RS 485 bus will need to take place once all boards are installed back into their enclosures and the field wiring connections are restored The first LevelMaster m...

Page 59: ...ng the first LevelMaster IMPORTANT NOTES It is assumed that the additional LevelMaster will be defined under the same location name as the first LevelMaster and therefore it will be stored in the same location file MasterLink opens the default location file or the file that was last saved in the procedure in section 5 3 6 Save the location file with a different name Ensure a unique ID is assigned ...

Page 60: ...the LevelMaster is available on the controller for retrieval by PCCU32 or WinCCU32 The configuration consists of setting up the LevelMaster application which handles the connection with the LevelMaster within the host controller The configuration involves Setup of the communication parameters for RS 485 communication between the host controller and the LevelMaster Defining the number of LevelMaste...

Page 61: ...k Entry Or go directly to the Entry screen by clicking the Entry icon 9 Click on the Station ID in the tree view Entry screen If there are multiple stations select the location being set up in the tree view so that it is highlighted 10 Click the Applications tab IMPORTANT NOTE This procedure assumes that the basic applications used by the flow computer are already instantiated See the PCCU help fi...

Page 62: ... the serial communication port has the correct communication module RS 485 For RMC 100s ensure that the hot swappable module is inserted and set for RS 485 operation To set up the number of tanks and communications parameters 1 Expand the Communications node in the navigation tree 2 Expand the LevelMaster node in the navigation tree 3 Click Setup under LevelMaster 4 On the Setup tab the value of t...

Page 63: ...se instructions it is assumed that COM2 will be used 8 Type COM2 in the serial port field 9 Click Send This will assign COM port 2 to the LevelMaster IMPORTANT NOTE Based on the configuration files that were loaded onto the board the remaining field default values should be sufficient to begin operation Figure 48 LevelMaster application Communications tab ...

Page 64: ...ally after this number In repeating instances for multiple tanks change the tank number and ID for each new tank 7 Set the correct number of sensors for this tank In this instance a Dual Level sensor is being used 8 Modify the ID to match the unit ID In this instance set ID to 1 Additional tanks will follow incrementally after this ID number 9 Set the interval to the time desired between data requ...

Page 65: ...column for each item that needs a display built Do this for each tank that a display is being built for 9 Click the node next to Display 10 Click the Display Group to edit or create a New Display Group To create a New Display Group see the PCCU32 help files 11 On the Setup screen the Group Description may be changed along with the Number of Displays 12 Click Send if any changes were made to the Gr...

Page 66: ...splayed and proceed to section 9 Troubleshooting IMPORTANT NOTES Level measurement can be calibrated as needed as described in section 7 1 Calibration for level measurement level bias Volume calculations are not displayed until the unit is calibrated for volume Configuration of the host controller for volume calculation is described in section 7 2 Calibration for volume calculations Additional ver...

Page 67: ...ure to poll on demand To configure the Trend application to store the LevelMaster data 1 Determine the data item or variable that will be trended For example level 1 measurement for tank 1 2 Determine the register app array reg address where the LevelMaster application is storing the chosen variable LevelMaster value a On the navigation tree expand Tank Data b Click the desired tank c Locate the d...

Page 68: ...fined correctly 1 Select the collect icon on the top tool bar 2 At the collection screen on the navigation tree expand TOTALFLOW 3 Expand Trend files and select the LevelMaster file 4 Select Screen as ouput and click Collect 5 Select the tab for the preferred view graph or table Figure 53 Verify that the defined variables and their values are displayed as expected Each variable defined in the tren...

Page 69: ...omputer or remote controller varies depending on the model For more details refer to the specific user manual for the model used in the installation This section provides the procedure for G3 and G4 devices as examples Saving the configuration files for a G4 flow computer To save the configuration files for a G4 flow computer 1 Click the Save and Restore icon folder with circular arrows on the PCC...

Page 70: ...sabled using the cycle option below It is disabled by default Example of digital output pinouts are provided in Figure 54 Host hardware digital outputs Table 8 Duty cycle parameters Parameter Description Suggested settings Cycle Option Enables on or disables off the Duty Cycle option On or enable Read Now Setting this flag to Yes causes the host to initiate an immediate read from all of the LevelM...

Page 71: ...ration This is actually combining two separate but useful functions Force poll of one or more LevelMasters function before and after a sale Switch display to LevelMaster readings goes directly to the information requested Wiring the Push to Read input button To wire the push to read input button 1 Locate the pulse or digital input and on the main electronics board as shown in Figure 55 2 Install t...

Page 72: ... the float was calibrated for may cause the float to sit slightly higher or lower in the fluid resulting in less precision in the measurement reading Calibrating the float in the field in this case is done by determining a new level factor and making a positive or negative adjustment to the level This is called a bias If the user has been manually gauging the levels and is confident that the measu...

Page 73: ...ng a correction factor to each section so that the calculated volume accurately reflects any irregularity IMPORTANT NOTE The strapping table configuration is applicable only when the LevelMaster is connected to a Totalflow host controller There is no capability for developing a strapping table when the LevelMaster is installed standalone MasterLink does not support this capability Strapping table ...

Page 74: ...hes for every section defined 6 Scroll down to navigate to Factors Per Section and type the factor for each section defined 7 Click Send to save the configuration 8 On the navigation tree click LevelMaster 9 Verify the volume calculations are displayed 10 After all calibration is complete and verified save the controller configuration as described in section 6 7 Save the configuration ...

Page 75: ...delines required for the site and determine the appropriate number of field personnel required to perform the removal IMPORTANT NOTE All service and maintenance procedures assume that the LevelMaster is installed in the tank and is wired Removing and restoring field wiring is required for all procedures It is assumed that the original wiring was done correctly and that the unit was working correct...

Page 76: ... communication connectors attached to the electronics board a When removing wiring from older boards 2018546 005 there may be one or two connectors b When removing wiring from newer boards 2104836 001 there are always two connectors one for each power and communications 4 Identify which wires connect to each connector pin If not color coded wires may be labeled or marked for easy identification a ...

Page 77: ... on the barrier board 4 Verify that measurements are being received and displayed by the LevelMaster application on PCCU Remove the unit from the tank Full removal from the tank is required to change the floats or the internal sensor assembly To remove the unit from the tank 1 Remove the cover as described in section 8 1 Remove the enclosure cover 2 Remove field wiring as described in section 8 2 ...

Page 78: ... of the enclosure If needed pull the wires gently to make sure they can be connected to the electronics board 8 Restore field wiring as described in section 8 3 Restore field wiring Remove the enclosure from the casing Full removal of the enclosure is required to replace the casing due to sensor assembly replacement It is assumed that the LevelMaster is out of the tank To remove the enclosure from...

Page 79: ...d while the ends of the tab are braced to the inside of the housing Establish local communication with electronics board All LevelMaster part replacement procedures require local communication with the electronics board Connecting to the board allows access for Basic parameter viewing Configuration backup save sensor data Configuration update download after hardware changes Verification after hard...

Page 80: ...e need for reconfiguration To save the configuration 1 Follow the steps described in section 8 8 Establish local communication with electronics board 2 When connection with the unit is successfully established select the Upload Download tab 3 Under Read data from the LevelMaster and save them to file use the default path and file name displayed or select a different path and or user defined file n...

Page 81: ...ess floats The older board version does not support these types of floats With the newer board version all float configurations are supported single or dual passive active or batteryless floats The upgrade process is described in detail in the LevelMaster upgrade kit application guide Board upgrades may replace an electronics board that is still in working condition IMPORTANT NOTE An existing conf...

Page 82: ...r electronics board 1 Remove the power and cover as described in section 8 1 Remove the enclosure cover 2 Disconnect the communication and power terminal connector s from the electronics board There may be one or two connectors depending on the board Do not remove wires from connectors They will be reinserted on the new board when it is placed in the enclosure 3 Hold the board by the edges and pul...

Page 83: ...e Hardware change click Hardware change 3 In the Select category drop down list select Electronics board 4 When prompted to download the configuration file click Next 5 When the upload download tab displays Figure 61 click the browse button Figure 61 MasterLink Upload Download tab 6 At the browser navigate to the folder where the existing configuration file was saved for example C Program Files x8...

Page 84: ...default file provides only calibration data for the specific length of the unit Other basic parameters must be manually configured to match the existing configuration IMPORTANT NOTE A generic file for the length of the sensor from the files provided with the MasterLink software can also be used but there may be a minor loss of accuracy precise calibration data for the sensor or coil assembly is on...

Page 85: ...the correct factory default configuration file 5 Under Send Data to the LevelMaster from file verify that the file path displays correctly Figure 63 Figure 63 LevelMaster Upload Download tab 6 Click Download Data to LevelMaster 7 Click OK when the download is complete ...

Page 86: ...a If the LevelMaster is an intermediate unit on a RS 485 bus i For boards with part number 2018546 005 verify that JP1 pins 5 6 and 9 10 are jumpered factory default ii For boards with part number 2104836 001 leave default configuration no change is required b If the LevelMaster is the only unit installed or it is the last unit on a RS 485 bus i For boards with part number 2018546 005 verify that ...

Page 87: ... laptop in a classified area ensure that explosive gasses are not present Tools required Small slotted screwdriver Phillips screwdriver Replace existing floats To replace one or more floats 1 Remove the power and cover as described in section 8 1 Remove the enclosure cover 2 Remove field wiring as described in section 8 2 Remove field wiring 3 Remove the unit from the tank as described in section ...

Page 88: ...ing and taking the unit out of the tank DANGER Serious damage to health risk to life When performing service or using a laptop in a classified area ensure explosive gasses are not present Tool and materials required Slotted screwdriver Wooden blocks to support the unit on the floor once extracted from the tank Replace sensor assembly and casing A replacement sensor assembly is typically shipped in...

Page 89: ...hat a hold can be established on the sensor Do not pull on the wire cable 9 Pull the assembly all the way out 10 Place the faulty sensor assembly in a safe place 11 Insert the bottom of the new sensor assembly through the top of the casing 12 Feed the assembly until the end is within a few inches of the top of the casing 13 Push the sensor in until it reaches the end of the casing bottom leaving t...

Page 90: ...sic setup for the unit ID baud rate etc Determine if the unit will be the only unit on the site If connecting to additonal units on a RS 485 bus determine if the unit is an intermediate or the last unit on the bus Use the MasterLink software package to run a test which will establish new offsets to match the LevelMaster to its new surroundings DANGER Serious damage to health risk to life When perf...

Page 91: ...s 5 015 5 018 Code Level Message Troubleshooting tip 0000 General No errors 0001 Float 0 Oil Detection of broken primary coil Primary coil may be broken Use the sensor test box to test the primary winding 0002 Float 0 Oil No float Float not recognized Float battery dead Float malfunction A to D gain too low A to D gain may be too low Use the test cable and the MasterLink program to increase the ga...

Page 92: ...n the following procedures specific wiring information is called by the common name for a component followed by its jumper number abbreviated J and pin number for example V BATT J4 1 If the host hardware is a 6790 RTU locate the correct pins on the RTU termination board If the host hardware is an XRC replace the J4 jumper number with the correct pins on the J6 jumper For other flow computers and r...

Page 93: ...isible in the annunciators LevelMaster annunciator is not assigned Follow instructions for setting up the display See section 6 4 Configure the LCD display Communication port configuration During polling the R is not replaced by an and or Depending on the baud rate the user may not see both but should see the R become at least one of these arrows Ensure data parameters are set correctly for the un...

Page 94: ... should be greater than 11 5 Vdc J1 2 POWER J1 1 POWER Negative voltage indicates damage to the barrier If the voltage received at the LevelMaster is greater than or less than the host voltage the power side of the barrier could be blown In older UL barriers the ground may be fused and can show smaller or even greater voltage than the LevelMaster is providing This is due to a floating ground The c...

Page 95: ...port 4 Remove the electronics board as described in section 8 12 1 Remove the existing board Place it in a safe place during the test 5 Disconnect the ribbon cable 6 Connect the sensor ribbon cable to the test box cable 7 Set the DMM to the 2K ohms range and attach the leads to the test box 8 Record the readings IMPORTANT NOTE On the backside of the test box there is a resistance table with differ...

Page 96: ...e value displayed Meaning of read U Return level s temperature errors warnings any ID respond U U03D020 96D011 94F076E 0000W000C5ac0 03 ID 20 96 Oil 11 94 Water No Errors CRC Use only with 1 LevelMaster connected Unn Return level s temperature errors warnings U03 U03D020 96D011 94F076E 0000W000C5ac0 03 ID 20 96 Oil 11 94 Water No errors CRC U N Return ID U N U03N03Cd746 03 ID CRC UnnF Return float...

Page 97: ...pass through 1 Connect the PC running PCCU32 to the flow computer with either an MMI cable RS 232 a USB cable or an Ethernet cable 2 Start PCCU 3 Click Entry on the toolbar 4 Click Communications on the navigation tree 5 Set the Unkey Delay to 1 6 Click Send 7 Click Terminal on the toolbar 8 To activate Tank Level Pass Through a Type TLPT 1 Tank Level Pass Through Activate at the prompt for XSerie...

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Page 99: ...0 R 10729 T1 10953 T2 10761 T3 10734 T4 10724 T5 10730 R 10728 T1 10955 T2 10763 T3 10734 T4 10722 T5 10728 R 10728 T1 10950 T2 10761 T3 10733 T4 10723 T5 10730 R 10728 T1 10950 T2 10765 T3 10733 T4 10726 T5 10730 R 10728 T1 10953 T2 10761 T3 10735 T4 10721 T5 10730 R 10727 T1 10953 T2 10763 T3 10735 T4 10723 T5 10731 DIST 022 93 TC 000 00 F0 DIST 011 13 TC 000 00 F1 U03D023 72D012 11F076E0000W000...

Page 100: ...nt of ABB The original US English version of this manual shall be deemed the only valid version Translated versions in any other language shall be maintained as accurately as possible Should any discrepancies exist the US English version will be considered final ABB is not liable for any errors or omissions in the translated materials Any and all derivatives of including translations thereof shall...

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ABB LevelMaster 7100, User Manual

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