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9
Troubleshooting
Troubleshooting covers new installations as well as existing installations. It is assumed with new installations that the problem is
related to a configuration issue or possible damage during shipping or installation. In existing installations that have been
working, it is assumed that the configuration is correct and that the issue is with a hardware failure. Error codes or messages are
displayed in MasterLink or PCCU32 to aid in resolving the issue. Take close note of what is displayed to determine what may be
the cause. Review and perform the suggested action in the troubleshooting tips. If unable to resolve the issue, contact ABB
support. See the back page of this manual.
Another tool for troubleshooting is provided in PCCU32 and is called Tank Level Pass Through. This feature allows the user to
communicate directly with the LevelMaster, outside of PCCU32, in Terminal mode. By using this feature, the user can
communicate at a base level. See Appendix A, Tank level pass-through.
Error messages
The MasterLink software displays errors messages in its Monitor tab which can help troubleshoot error conditions or component
failure. Each condition has an assigned error code. Take note of the codes or messages displayed as they can help ABB
support personnel or developers determine the cause of the problem.
IMPORTANT NOTE: Error codes from LevelMasters with boards part number 2104836-001 (firmware version 7.0
and later) are not listed in this section, but they are displayed with complete description on the MasterLink monitor
tab.
Table 9 provides the error code description for legacy boards part number 2018546-005. It is included here to
provide additional reference information to what appears on the MasterLink screens.
Table 9: Error messages for board part number 2018546-005 (firmware versions 5.015 – 5.018)
Code
Level
Message
0000
General
No errors
0001
Float 0 (Oil)
Detection of broken primary coil
No float
Float not recognized
0002
Float 0 (Oil)
Float battery dead
Float malfunction
A to D gain too low
Float position out of range, float is not positioned
0003
Float 0 (Oil)
in sensor range
Analog-to-digital converter saturation (gain too
0004
Float 0 (Oil)
high), or sensor failure
Level bias calculation error. Compensated value
0005
Float 0 (Oil)
below 0" or above 655", or wrong calibration file
for this hardware (board/sensor)
0010
General
Broken primary coil
Measurement error – gain set too high or bad
0020
General
sensor element
Analog-to-digital converter saturation (gain too
0030
General
high)
Troubleshooting tip
Primary coil may be broken. Use the sensor test box to test
the primary winding.
A to D gain may be too low. Use the test cable and the
MasterLink program to increase the gain of the analog-to-
digital converter. If this does not solve the problem, the top
float may be malfunctioning. Remove sensor and replace
float.
The float is not positioned over the windings on the sensor.
Check that the float is present on the sensor or is not stuck at
the top of the tank (casing). Or if the tank is empty, the float
may be at the very bottom of the casing and out of sensor
range.
Reading for the top float has saturated the analog-to-digital
converter. Reduce the gain setting using the MasterLink
program.
Check the value entered for level offset for the top float and
verify that it has been entered correctly.
Use the LevelMaster sensor test box to test the primary coil.
Connect a laptop to the sensor board. Using test cable and
the MasterLink program, reduce the analog-to-digital gain. If
reducing the gain does not eliminate the error condition, the
sensor wiring may have failed. Use the sensor test box and
test the sensor primary and secondary windings. If neither of
the above solves the problem, then the sensor PC board may
be defective.
Reduce the analog-to-digital gain. After installation, proximity
of metal tank walls or other metal close to the sensor may
LevelMaster 7100 User manual 2105835 Rev AA | 81
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Table of Contents
Troubleshooting
