ABB LevelMaster 7100 User guide

Upgrade to support batteryless floats
Introduction
This guide is designed for typical installations only. Service and maintenance must
be performed by personnel knowledgeable of the ABB Totalflow
®
LevelMaster.
Maintenance personnel must also be knowledgeable of local and national codes as
they apply to hazardous areas, communication wiring, and electrical wiring.
IMPORTANT NOTE:This guide does not address any requirements
for the removal or installation of product(s) in hazardous (classified)
locations. Refer to the installation instructions and local and national
electrical codes for installation requirements in hazardous (classified)
locations.
Purpose
This guide provides instructions and information for upgrading an existing electronic
headboard (2018546-005) and battery-driven (active) floats with the new headboard
(2104836-001) and batteryless floats.
Application guide
Liquid level sensor
LevelMaster 7100
Upgrade kit

Additional information
Additional free publications and the software for the LevelMaster are available for
download at www.abb.com/totalflow or by scanning this code:
Document name Part number
LevelMaster user manual 2018374
LevelMaster startup guide 2103656
MasterLink software version 2.0 2100197-005
For questions that are not answered in this guide or other documentation, or if
experiencing issues downloading the software, call a local ABB representative, or
call the main office number listed on the back page of this guide.
Assumptions
The following apply to this guide:
— The LevelMaster to be upgraded is installed to measure levels for water, oil or
both. The upgrade kit can be used to upgrade the unit for single or dual
batteryless float operation.
— MasterLink software version 2.0 is used to configure the upgraded LevelMaster.
— If the LevelMaster is connected to an ABB flow computer or remote controller,
the LevelMaster application should already be configured.

2105824-001 rev. AA | 3
1 Safety warning and notes symbols
Read and follow the instructions contained in this guide, before and during
equipment installation. Failure to do so could result in bodily injury or equipment
damage.
1.1 Safety conventions
WARNING – Bodily injury/property damage/equipment
damage. This symbol, in conjunction with the signal word
"WARNING", indicates a potentially dangerous situation. Failure to
observe this safety information may result in death or severe injury.
The text may state the hazard, what to do or not do to avoid the
hazard, and what the result would be if not followed.
CAUTION – Equipment / Property damage. This symbol, in
conjunction with the signal word "CAUTION", indicates a potentially
dangerous situation. Failure to observe this safety information may
result in property damage. The symbol may also be used for minor
injury warnings. The text may state the hazard, what to do or not do to
avoid the hazard, and what the result would be if not followed.
IMPORTANT NOTE: This symbol indicates operator tips, particularly
useful information, important information about the product, or to clarify
a concept. The signal words "IMPORTANT NOTE" do not indicate a
dangerous or harmful situation.
1.2 Potential safety hazards
Installation, commissioning, and maintenance of this equipment must only be
conducted by personnel authorized to work on electrical installations, and in
accordance with relevant national and local codes.
The LevelMaster operating voltage range is 9 Vdc to 15 Vdc.
There are no hazardous voltages present.

4 | 2105824-001 rev. AA
2 Upgrade kit overview
2.1 Upgrade kit contents
The batteryless float upgrade kit (part number 2105820) contains the following:
Table 1: Upgrade kit contents
Qty Description Part number Notes
1 Batteryless float (oil level) 2103766-006 Float Kit part number (includes
only floats): 2018392-017
1 Batteryless float (water level) 2103766-007
1 Electronic headboard 2104836-001
Firmware version 7.0
Required for batteryless floats
2.2 Unpacking and inspecting
Unpack the upgrade kit and inspect for damage and missing or incorrect parts.
IMPORTANT NOTE: If there is any damage to the shipping carton,
keep it and the packing materials until the contents are inspected and
found to be free of damage.
CAUTION – Equipment damage. A static electric discharge can
result in damage to the electronic board. Wear a grounding strap to
eliminate static electricity when inspecting or handling the board.
1. Unpack and inspect each float.
2. Unpack and inspect the electronic board.
IMPORTANT NOTES: The new board (2104836-001) has two
separate ports for both RS485 and power in constrast with the single
port for the older board version (2018546-005).
Make sure the electronic board has two removable terminal connectors
for power and the RS485 communication port. These connectors may
be needed if the existing connection has a single port.
3. Unpack and inspect optional equipment, if purchased.
4. Check for missing, incorrect, or damaged parts. Contact the ABB Representative
to replace missing, incorrect, or damaged parts.

2105824-001 rev. AA | 5
3 Prepare before the upgrade
3.1 Plan for unit access removal and reinstallation
Upgrading the LevelMaster for batteryless float support requires removal of all
connections and pulling the LevelMaster out of the tank. Plan for the following:
1. Removal of the unit requires access to the top of the tank. Follow company
guidelines and safety procedures to access the sensor.
2. Determine the number of technicians required to remove and reinstall the unit.
Removal or reinstallation may require more than one person depending on the
length (height of the tank) and weight of the unit.
3.2 Install MasterLink version 2.0
The MasterLink version 2.0 software supports batteryless float configuration and is
required for the upgrade. MasterLink version 2.0 is backwards compatible and
therefore supports the older electronic boards as well as configuration files.
IMPORTANT NOTE: Installation of the MasterLink version 2.0 does not
upgrade an existing MasterLink version. The new version is a new
installation independent of the previous version and therefore there will
be two separte instances of MasterLink in the same laptop. The new
instance will not have the 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:
1. Go to the Liquid level sensor LCM7100 page, click the Downloads tab.
2. Scroll down to locate and select Software.
3. Click the PDF icon to download the software.
4. Install the software on the PC or laptop that will connect to the LevelMaster.
Take note of the path of the installed directory.
5. (Optional) Copy any required data (configuration) file from the older MasterLink
installation to the new main installation folder. Data files have the .dat and .tlm
extensions and reside in the main MasterLink directory by default. The .dat files
contain configuration and calibration data. The .tlm files contain location files.
The location files define the names of the location and the LevelMasters at
those locations. The number of configuration or location files depends on the
number of units and locations.
IMPORTANT NOTE: If the files from the old MasterLink directory were
kept with their default names, they will overwrite files with the same
default names in the new MasterLink main folder. To avoid overwriting
any default files in the new installation, rename the files being copied or
save into another folder.
3.3 Determine which configuration to use
The new electronic board must be updated to reflect the upgrade. The board can be
configured using the existing configuration or using a pre-defined configuration file
provided with the MasterLink version 2.0 software.

6 | 2105824-001 rev. AA
Determine which configuration to use based on the upgrade scenario:
— Use the existing configuration if available. The configuration file of the
LevelMaster contains calibration information for the internal sensor assembly
(sensor coil). Since the sensor assembly is not being changed in the upgrade,
the calibration data remains the same and it is still applicable to the unit.
IMPORTANT NOTE: Because the existing configuration corresponds
to an electronic board that is different than the new board, the accuracy
of the unit will be affected by using an existing file.
— Use a pre-defined (default) configuration file if the existing configuration file
cannot be obtained. MasterLink version 2.0 provides configuration files for dual
batteryless float operation for different unit lengths. The files for the new
electronic board are located in the MasterLink\DefaultDat\7.0 Head board folder.
The names of the default files indicate which sensor length they apply to.
3.4 Required tools and materials
The following items are needed to perform the upgrade
Tools and material:
— Phillips screwdriver
— Small slotted screwdriver
— 24 inch pipe wrench
— Wooden blocks or other means to support the sensor on the floor when
removed from the tank
— Grounding strap
Cables:
Direct connection to the electronic board is required for configuration and monitoring
during the upgrade. The cables and adapters listed in Table 2 (page 7) are used for
this connection.
IMPORTANT NOTES: Different cable adapters and RS485-to-RS232
converter cables are required for each, the new board (part number
2104836-001) and the previous board (part number 2018546-005).
Make sure you select the correct cables.
CAUTION – Equipment damage. The RS485-to-RS232 converter
cables have 1 or 2 batteries (9 Vdc) which supply power to the boards
during direct connection. No additional voltage source is required
during direct connection for configuration.
Do not use two batteries to suply power to the new board (part number
2104836-001). The board will be damaged when the supplied power is
greater than 15 Vdc (2 fully charged 9 Vdc batteries can supply up to
18 Vdc).
To prevent battery drain when converter cables are not in use, make
sure the red wire is removed from the positive terminal contact on the
battery holder (Figure 1).

2105824-001 rev. AA | 7
Table 2: Cable and adapters for direct connection to the LevelMaster
Board Description Part number Notes
2104836-001
(New)
Cable adapter 2100250 - 002
Cable end connecting to the board has
a 2-position terminal connector for
power and a 4-position terminal
connection for the communication port
(RS485)
See Figure 1.
RS485-to-RS232
Converter cable 2100241 - 005 Contains 1 battery (9 Vdc). See Figure 1.
2018546-005
(Legacy)
Cable adapter 2100250 - 001
Cable end connecting to the board has
a single 6-position terminal connector
for both power and the communication
port.
RS485-to-RS232
Converter cable 2100241 - 002 Contains 2 batteries (9 Vdc).
Both boards
RS232 to USB
converter cable
Third-party
manufacturer
Use if connecting to a USB port on a
laptop (if legacy RS-232 ports are not
available on the laptop)
Figure 1 shows the cable converter and adapters required for connection to the new
board (2104836-001).
Connect to Level Master board
P/N 2104836-001
Cable Adapter
P/N 2100250-002
9VBatt
RS232/RS-485 converter
P/N 2100241-005
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.
+
Figure 1: Cables required for connection with new board (P/N 2104836-001)

8 | 2105824-001 rev. AA
4 Upgrade procedures
4.1 Remove the sensor from the tank
Removal of the sensor requires removal of power and other connections from the
LevelMaster. Devices that may be connected to the LevelMaster may include
additional LevelMasters (RS485 bus), flow computers or controllers, an electronic
barrier card for hazardous locations. For details on additional connections refer to
the LevelMaster user manual (see the Additional information section).
In this procedure the existing electronic board is removed. Make sure it is removed
carefully to avoid damage and loss of its configuration. The existing configuration is
obtained for use on the new board if retaining sensor calibration data.
Figure 2 shows the top of an installed LevelMaster. Use as a reference for this
procedure.
TANK PORT
BUSHING
CORD
CONNECTOR
TANK
ELECTRONICS
ENCLOSURE
NUT
Figure 2: Top of the Level Master
To remove the LevelMaster from the tank:
1. Remove the cover from the electronic enclosure.
2. Use the small slotted screwdriver to remove the power and communication
connector.
IMPORTANT NOTE: There may be one or two connectors used to
connect to the existing board. If using a single connector rewiring to
two connectors will be required to connect to the new board. The
communication pinout is also different on the new board.
3. Identify which wires connect to each connector pin. If not color coded, wires may
be labeled or marked for easy identification.
a. Identify or label the two wires used for power (+V, -V).
b. Identify or label the wire pairs used for communication (+T, -T, +R, -R).

2105824-001 rev. AA | 9
4. Remove the wires from the connector(s). If two connectors were removed, keep
for rewire.
5. Hold the existing board by the edges, and pull it out slowly.
6. Unplug the 16-pin connector at the bottom of the board to detach the board from
the sensor assembly inside the casing.
7. Place the removed board in a safe place (protect from static
electricity).Connection to the board is required to obtain configuration.
8. Unscrew the conduit to detach from enclosure. Leave wire ends hanging.
9. Replace the cover on the electronics enclosure.
10. Loosen the nut on the cord connector.
IMPORTANT NOTE: There should be no cord connector on high
pressure units.
11. Unscrew the tank port bushing.
12. Remove the LevelMaster from the tank and lay it on the ground using the
wooden blocks underneath for support (If no wooden blocks are available use
any stable and even support to keep the unit from rotating while in horizontal
position).
13. Proceed to replace the existing floats.
4.2 Replace the existing floats
To replace existing floats:
1. Remove the float clamp from the bottom of the casing.
2. Slide the float(s) off the bottom of the casing.
3. Slide the new float(s) onto the bottom of the casing. If using two floats, install in
the correct order (Figure 3).
IMPORTANT NOTE: Position the float(s) correctly so that the text on
the float label would be in the upright position when the LevelMaster is
inserted back into the tank.
a. Install the oil level float first.
b. Install the water level float second.
OIL
FLOAT
WATER
FLOAT
1 2
TOP OF
LEVELMASTER
Figure 3: Positioning the floats for dual float configuration
4. Slide the float clamp back onto the bottom of the casing.
5. Use a Phillips screwdriver to tighten the clamp 1 inch above the bottom of the
casing. Considerable force may be required to lock the clamp on tight.

10 | 2105824-001 rev. AA
4.3 Obtain existing configuration file
With this procedure use the MasterLink software to view or obtain the configuration
of the unit if the configuration file was not previously saved. It is assumed that the
existing board removed in section 4.1 is in working condition. If the board is defective
or communication with it is no longer possible, proceed to section 4.4, Insert the new
electronic board.
4.3.1 Connect to the existing board
To connect use the following (see Table 2 in section 3.4, Required tools and
materials in page 6, for details):
— The RS485 to RS232 converter (2100241 - 002) with the cable adapter
(2100250 – 001, the cable with a single terminal connector at one end)
— If using an USB port on the laptop, use the serial-to-USB adapter.
IMPORTANT NOTE: Make sure to connect the positive terminal (red
wire) to the positive contact on the battery holder.
To obtain the configuration saved on the board:
1. Connect the laptop directly to the electronic board using the correct cable and
adapters for the board.
2. Start the MasterLink software.
3. Click the Comm. Port drop down list.
4. Select the laptop communication port used.
5. Leave Baud Rate at 9600. It assumed the board was at the default baud rate. If
not set at the default rate, select the other option (1200).
6. Click Setup LevelMaster.
7. Select I have only one LevelMaster connected to communication port and I
want to set it up.
8. Click Setup LevelMaster.
9. Observe the messages displayed on the monitor screen. Verify that the
communication is successful. The screen should indicate the number of tries
and 100% success.
10. When prompted to add the LevelMaster to the list, click No.
11. If planning to use a generic (default) configuration file, proceed to view and take
note of the configuration in section 4.3.2, View configuration.
12. If planning to use the existing configuration for the new board, proceed to save
the configuration in section 4.3.3, Save the configuration.
4.3.2 View configuration
If not downloading an existing configuration, the LevelMaster must be configured
manually to match the configuration in the existing board. Use this procedure to
obtain the basic configuration values for the unit.
To view the configuration:
1. Select Add Advanced Setup tabs.
2. Select the More Items tab. The screen displays the Data from LevelMaster.
3. Under the Basic Items category locate the following parameters and take note of
the values:

2105824-001 rev. AA | 11
a. Sensor name
b. Sensor unit number (or sensor or LevelMaster ID)
c. Baud Rate
d. Coil length (sensor assembly length in inches)
4. Determine the RS485 bus termination configuration by checking the positions of
the jumpers on JP1 on the board (Figure 4):
a. Pins 5-6 and 9-10 are jumpered (factory default). The unit is an
intermediate sensor on the bus.
b. Pins 5-6, 7-8, and 9-10 are jumpered. The unit is the only sensor or the last
sensor on the bus.
Figure 4: RS485 termination
4.3.3 Save the configuration
To save the configuration in the laptop:
1. Select the Upload/Download tab.
2. 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
name (Ensure the file keeps the .dat extension).
IMPORTANT NOTE: The default path for the saved file depends on the
MasterLink version used. The files are automatically saved in the main
installation directory of each version. Make sure to take note of the
name of the file and the location chosen.
3. Click Read and Save Data to File.
4. Click OK when saving the configuration is complete.
5. Disconnect the laptop from the board.
4.4 Insert the new electronic board
This procedure connects the electronic board to the sensor assembly and positions
the board inside the enclosure. Make sure that the communication and power ports
are accessible for local connection from the laptop for configuration.
To install the new board:
1. Remove the cover from the electronic enclosure.
2. Remove the new board from the bag.
3. With the small slotted screwdriver remove the terminal connectors from the
power and communication (RS485) ports (Figure 5). Do not lose the connectors,
they will be needed for final wiring of the unit when placed back in the tank.

12 | 2105824-001 rev. AA
Figure 5: Removing terminal connectors
4. Plug the 16-pin connector from the sensor assembly into the new electronic
board. The connector is keyed so it will only plug in one way. Push some of the
excess cable back down through the bottom of the sensor assembly while
sliding the electronic board back into position. Allow a small cable loop to fold
back towards the top of the enclosure.
5. Brace the electronic board inside the housing by using the yellow fiberglass tab
inserted into the enclosure.
6. Bend the tab gently into a semicircle using the thumb and forefinger, making
sure the apex of the arch is placed against the board while the ends of the tab
are braced to the inside of the housing.
7. Proceed to configure the board.
4.5 Configure the new board
MasterLink version 2.0 is required to configure the new board.
4.5.1 Connect to the new board
To connect use the following (see Table 2 in section 3.4, Required tools and
materials, in page 6, for details):
— The RS485 to RS232 converter (2100241 – 005) with the cable adapter
(2100250 – 002, the cable with two separate terminal connectors at one end)
— If using an USB port on the laptop, use the serial-to-USB adapter.
IMPORTANT NOTE: Make sure to connect the positive terminal (red
wire) to the positive contact on the battery holder.
T+T+T-T-
+-
RS485
PORT
POWER
PORT
REMOVE
TERMINAL
CONNECTORS

2105824-001 rev. AA | 13
To configure the new board:
1. Connect the laptop directly to the electronic board using the correct cable and
adapters for the board.
2. Start the MasterLink version 2.0 software.
3. Click the Comm. Port drop down list.
4. Select the laptop communication port used.
1. Leave Baud Rate at 9600 (factory default).
2. Click Setup LevelMaster.
3. Select I have only one LevelMaster connected to communication port and I
want to set it up.
4. Click Setup LevelMaster.
5. Observe the messages displayed on the monitor screen. Verify that the
communication is successful. The screen should indicate the number of tries
and 100% success.
6. When prompted to add the LevelMaster to the list, click No. The unit can be
added later.
7. If using the existing configuration, proceed to section 4.5.2, Configure the new
electronic board with the existing configuration.
8. If using a default configuration file, proceed to section 4.5.3, Configure the new
electronic board with a default configuration.
4.5.2 Configure the new electronic board with the existing configuration
Use this procedure if configuring the new board with the existing configuration file
saved in section 4.3.3, Save the configuration.
In this procedure the existing configuration is downloaded to the new board. The ID,
baud rate, and calibration data from the previous board are saved in the unit. The
float configuration must be changed to reflect the batteryless floats.
To download the existing configuration:
1. Select the Upload/Download tab.
2. Under Send data to the LevelMaster from the file, click the browse ([…]) button.
3. At the browser, navigate to the folder where the existing configuration file was
saved (for example, C:\Program Files (x86)\ABB\MasterLink).
4. Locate and select the configuration file.
5. Click Open.
6. Click Download Data to LevelMaster.
7. Click OK when download is complete.
8. Click the Setup tab.
9. Under Make Hardware change, click Hardware change.
10. In the Select category drop down list, select Float Configuration.
11. Click Next.
12. Select Float mode Dual Batteryless.
13. Click Next.
14. Click Next again to confirm that the float configuration will be changed.
15. Click OK when configuration change is complete.

14 | 2105824-001 rev. AA
16. Click the Monitor tab.
IMPORTANT NOTE: Before the configuration to batteryless floats is
completed, the monitor screen displays errors because the existing
configuration does not support or recognize the floats.
17. If errors are displayed, clear the errors and make sure no additional errors are
displayed. If errors do not clear see section 5, Troubleshooting.
18. If errors cleared, verify that the level and temperature readings display expected
values based on the float position and temperature. See section 4.6, Verify
measurements.
19. If the LevelMaster is the only unit installed or it is the last unit on a RS485 bus,
proceed to section 4.5.4, Configure RS485 termination.
4.5.3 Configure the new electronic board with a default configuration
Use this procedure if configuring the new board with one of the default files included
with the MasterLink software. Using the 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. Use the information obtained in section 4.3.2,
View configuration.
To configure:
1. Click the Upload/Download tab.
2. Under Send data to the LevelMaster option, click Browse […].
3. At the browser, navigate to the default files folder applicable to the new board.
For example, C:\Program Files (x86)\ABB\MasterLink\DefaultDat\7.0 Head
board.
4. Locate the file for the correct length of sensor and click Open.For example, for a
20 foot sensor, select the "Dual_20ft_batteryless.dat" file (Figure 6).
Figure 6: Locating the correct configuration file
5. Under Send Data to the LevelMaster from file, verify that the file path displays
correctly (Figure 7).

2105824-001 rev. AA | 15
Figure 7: Downloading correct configuration to the LevelMaster
6. Click Download Data to LevelMaster.
7. Click OK when the download is complete.
8. Click the Setup tab (Figure 8).
Figure 8: Configure the ID and Baud Rate

16 | 2105824-001 rev. AA
9. Change the LevelMaster ID by typing the correct ID into the New LevelMaster ID
field and clicking Set New ID.
10. If needing to set another Baud rate, click Set <…>Baud Rate. The next
applicable value for the baud rate is the one shown on the button. For example,
if the value shown is 19200, clicking on the button, will set the rate to 19200.
IMPORTANT NOTES:
Baud rates for units connected to a RS485 bus must match.
Power to the unit must be reset for the new baud rate to take effect.
Take note of the rate defined. The new rate is needed to connect to the
unit again and must be selected prior to establishing communication.
11. From the monitor screen verify that the level and temperature readings display
expected values based on the float position and temperature. See section 4.6,
Verify measurements.
12. If the LevelMaster is the only unit installed, or it is the last unit on a RS485 bus
proceed to section 4.5.4, Configure RS485 termination.
4.5.4 Configure RS485 termination
Use this procedure if the LevelMaster is the only unit or the last unit on a RS485 bus.
Termination configuration can only be done on software (no jumpers are available on
the new board).
1. Click on the Monitor tab and select Add Advanced Setup tabs.
2. Click the More items tab.
3. Select Show memory map.
4. Scroll down to locate the 844 memory address. The description of this memory
location is RS485 bus termination (Figure 9).
Figure 9: RS485 termination

2105824-001 rev. AA | 17
5. Double-click on RS485 bus termination.
6. When the edit box displays (Figure 10), if the value is 0, change the value to one
(1). The value of 1 configures the unit as the last sensor on the RS485 bus.
Figure 10: Configure the LevelMaster to terminate RS485 bus
7. Click Send New Value.
8. Verify that the RS485 termination address is now set to 1 (Figure 11).
Figure 11: RS485 termination for the last sensor
IMPORTANT NOTE: The RS485 bus termination value for intermediate
LevelMasters on the RS485 bus should be 0. Units are configured as
intermediate sensors by default.
4.6 Verify measurements
Before reinstalling the tank, make sure that the new electronic board is functioning
correctly and the sensor is able to detect and measure the temperature and the float

18 | 2105824-001 rev. AA
positions. There should not be errors displayed and the monitor tab should display
the correct level measurement.
To verify that measurements are correct:
1. Click the Monitor tab to observe the temperature and level measurements using
the newly downloaded setup information.
2. Verify that the measurements reflect expected values:
a. The temperature should be approximately the temperature at the location of
the LevelMaster. If configuring the unit outside, then the ambient
temperature should display.
b. The level(s) should indicate the position of the float(s).
3. Slide the floats to several positions on the sensor and verify that the screen
updates and reflects the correct level for the floats.
4. Proceed to ground the unit if required (section 4.7) or reinstall the unit as
described in section 4.8, Reinstall the LevelMaster into the tank.
4.7 Ground the electronic board
WARNING – Bodily injury/ property damage. Grounding the
LevelMaster 7100 in a hazardous location must meet the requirements
as specified in the National Electrical Code (NEC) or the Canadian
Electrical Code (CEC).
If an earth ground is available, ground the electronic board as follows:
1. Connect the EARTH connector to the ground connector as shown in Figure 12.
Figure 12: Grounding the electronic board

2105824-001 rev. AA | 19
2. Jumper pins 2 and 3 on J12.
4.8 Reinstall the LevelMaster into the tank
For additional details and scenarios for reinstalling the sensor into the tank refer to
the LevelMaster user manual (see the Additional Information section).
To reinstall the unit:
1. Secure the cover back on the electronic enclosure.
2. Lift the unit from the floor and prepare to reinsert it into the tank.
3. Once positioned for reinsertion, slowly lower the LevelMaster down through the
hole in the tank. Make sure that the unit is vertical until it is resting on the
bottom. If there is sludge at the bottom, work the unit up and down a few times
to reach the bottom.
4. Screw the tank port bushing into the tank port opening.
5. Tighten the nut on the cord connector.
6. Plumb the cable or conduit into the electronics enclosure for the
communications and power wiring.
7. Proceed to restore the field wiring next.
4.9 Restore field wiring
The new electronic headboard has two separate ports for communication and power
in contrast with the single port on the previous board (Figure 13).
If a single connector was wired to connect to the previous board, replace it with the
two connectors that came with the new board and were removed in section 4.4,
Insert the new electronic board.
If two connectors were already in use, rewire the connector for communication. The
pinout for RS485 in the previous board does not match that of the new board.
Figure 13: Electronic ports pinouts
For additional details on the connections to other ABB equipment refer to the
LevelMaster user manual (see Additional Information section).
4.9.1 Wiring for power
To rewire for power:
1. Remove the cover from the enclosure.
2. Loosen the screws on the power connector (2-position terminal connector).

20 | 2105824-001 rev. AA
CAUTION – Equipment damage. The LevelMaster can be powered
from the serial (COM) ports on an ABB Totalflow flow computer or
remote controller. The output voltage at these ports is dependent upon
the external power supply connected to the device.
Before connecting the LevelMaster to these ports, ensure that the flow
computer or remote controller input voltage does not exceed 15 Vdc.
Connecting the LevelMaster to devices with an input power larger than
15 Vdc (for example devices powered by 24 Vdc voltage sources) will
result in damage to the LevelMaster because the output power from the
serial port (VOUT) will also be larger than 15 Vdc. Use an independent
power source if unable to power the unit from the flow computer or
controller.
3. Insert the wires in the power connector observing correct polarity (Figure 14).
a. Connect to flow computer/remote controller COM port if VOUT is 12 Vdc.
b. Connect to alternate power source if VOUT at the COM port is greater than
12 Vdc.
Figure 14: Wiring for power
4. Insert the power connector back into the board.
5. Verify that the power LED (labeled D9 and 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.
4.9.2 Wiring for communication
To wire for communication:
1. Loosen the screws on the communication connector (4-position terminal
connector).
2. Insert the wires in the connector observing the pinout.
a. If the unit is the only unit connected to a flow computer or remote controller
wire as shown in Figure 15.