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ABB TOTALFLOW LevelMaster Series Startup Manual
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ABB TOTALFLOW LevelMaster Series Startup Manual

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LevelMaster Start-Up Guide
MEASUREMENT & CONTROL SYSTEMS

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Summary of Contents for ABB TOTALFLOW LevelMaster Series

  • Page 1 LevelMaster Start-Up Guide MEASUREMENT & CONTROL SYSTEMS...
  • Page 2 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 and omissions in the translated materials.

  • Page 3: Basic Installation Procedure

    Basic Installation Procedure 1. After preparing the tank for installation, use Teflon tape or another sealing material on the cord connector threads. 2. Screw the cord connector into the bushing (see Figure 1). Figure 1. Tank Port Bushing Preassembly 3. Add Teflon tape or another sealing material to the tank port bushing threads, and slide the cord connector and bushing into the bottom of the LevelMaster with the cord connector on top.
  • Page 4 MODEL 7100 LEVELMASTER OIL FLOAT TANK WATER FLOAT SENSOR MUST BE ON BOTTOM OF TANK Figure 3. Typical LevelMaster Oil and Water Tank Installation Location Wiring The wiring schematics differ within the LevelMaster depending on site location. Non-hazardous sites do not require the use of a barrier board, while hazardous sites do require one.
  • Page 5 XFC Host Wiring The Totalflow XSeries flow computer supports the LevelMaster, while performing their duties as a flow computer. All XFC models are wired identically. See Figure 4 for wiring instructions. Figure 4. XFC Wiring Interconnect...
  • Page 6 XRC Host Wiring The Totalflow XSeries Remote Controller (XRC) has supporting firmware for the LevelMaster. Additionally, the LevelMaster can be connected to either Comm 1 or Comm 2. All XRC models are wired identically. See Figure 5 for wiring instructions. Figure 5.
  • Page 7 LMC Host Wiring The LevelMaster Controller (LMC) board is a modified version of the Totalflow XSeries Remote Controller (XRC) board that has the full functionality of the XRC board removed. Additionally, the LevelMaster can be connected to either Comm 1 or Comm 2. See Figure 6 for wiring instructions.

  • Page 8: Software Setup

    LevelMaster Board Jumper Settings The LevelMaster electronics board (2018546-xxx) has jumpers that need to be configured to complete the wiring process. The jumpers are in place for the termination of the last board on an RS-485 bus. As this is the case, the last board is jumpered differently than the first and intermediate boards.
  • Page 9 While we are only looking at these two setup configurations within the confines of this reference guide, additional setup configurations do exist. Please refer to the LevelMaster User’s Manual for further information. MasterLink Software When the equipment configuration does not contain a host unit such as a XRC or flow computer, MasterLink is the primary tool used for setup and calibration.
  • Page 10 2. After powering up the laptop, start the MasterLink software program by clicking the corresponding icon. 3. When the Totalflow MasterLink window appears, select Setup Sensor from the main toolbar. From the drop-down menu, select Advanced Setup LevelMaster. 4. In the New LevelMaster Setup window, the user can select one of two options to set up the LevelMaster (see Figure 9).
  • Page 11 the Set New ID button. A dialog box appears asking if the user wants to update the new ID to the list. Click the OK button. Figure 10. LevelMaster Setup Screen 9. Also within the Setup tab, the user can calibrate the LevelMaster by entering the actual level value in the ‘Tank Level 1’...
  • Page 12 Figure 11. Upload/Download Data Screen XSeries Software Setup Totalflow’s XSeries System (XFC or XRC) can be setup to provide support for the LevelMaster. Either the XFC or XRC is connected to the LevelMaster via RS-485 protocol. The following procedure assumes that there are no other LevelMaster applications already installed.
  • Page 13 5. In the Applications tab, locate Application Slot 20. Click in the Type field to open the drop-down menu, and select LevelMaster. 6. Click the Send button. The application will load. 7. Locate the LevelMaster application in the tree view, and click on it (see Figure 13).
  • Page 14 Figure 15. Advanced Communication Setup 14. From the main PCCU toolbar, select Operate, then File Utilities and then LevelMaster Request Block Editor from the drop-down menu. 15. In the LevelMaster Request Block Editor window, enter in the Application number (20), the Tank Number, number of Sensors, unit ID and the time Interval (see Figure 16).
  • Page 15 16. Save the settings by selecting File from the toolbar and selecting Save As. Note the path where the file is saved. If more than one tank is installed, repeat the above steps for each tank. 17. From the main PCCU toolbar, select Operate, then File Utilities and then File Transfer from the drop-down menu.

  • Page 16: Error Codes Troubleshooting

    PCCU32 Tank Setup Screen As the user sets up each tank in the Tank Setup screen, the lower portion of the screen allows them to enter information to create a strapping table. The user will need to enter the number of tank sections and then complete the following information for each section (x being the section number): Section (x) Height...
  • Page 17 Troubleshooting Table Code Message Action 0000 No errors Float 0 (Top Float) 0001 No ICOMP signal. Detection of The box needs to be tested. If broken primary coil. OPEN, the sensor needs to be replaced. 0002 V0 through V3 below threshold. Cycle the power.

  • Page 18: Testing The Sensor

    Error Code 0030 1. Click the More Items tab (see Figure 17). In this area, the user can view all of the information that concerns this particular LevelMaster. As the description and corresponding values are here, locate Gain Setting and double-click on it. Figure 17.
  • Page 19 5. Set the ohmmeter to the 2K range, and attach the leads to the test box. 6. Record the readings for future reference. 7. On the backside of the test box is a resistance table for different windings for each sensor. If the winding readings are +/- 5.0% of the resistance table on the backside of the test box, the sensor passes the test.
  • Page 20 ABB Inc. Totalflow Products 7051 Industrial Blvd. Bartlesville, Oklahoma 74006 Tel: USA (800) 442-3097 International 001-918-338-4880...

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Totalflow levelmaster 7100