Level Control Unit

LevelControl Basic 2

Signalling Module
Current Measuring Module

Supplementary Operating
Manual

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 Legal information/Copyright
Supplementary Operating Manual LevelControl Basic 2

Original operating manual

All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.

© KSB SE & Co. KGaA, Frankenthal 19/01/2018

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 Contents

Contents
1 General....................................................................................................................................................  4
2 Safety ......................................................................................................................................................  5
2.1 General.............................................................................................................................................................. 5
3 Transport/Temporary Storage/Disposal...............................................................................................  6
3.1 Condition upon delivery .................................................................................................................................. 6
3.2 Transport........................................................................................................................................................... 6
3.3 Storage .............................................................................................................................................................. 6
4 Description .............................................................................................................................................  7
4.1 Compatibility .................................................................................................................................................... 7
4.2 General description .......................................................................................................................................... 7
4.3 Technical data................................................................................................................................................... 9
5 Installation at Site ................................................................................................................................  11
5.1 Connecting the signalling module ................................................................................................................ 11
5.2 Connecting the current measuring module.................................................................................................. 13
6 Commissioning/Start-up/Shutdown...................................................................................................  15
6.1 Commissioning/start-up ................................................................................................................................. 15
6.2 Shutdown........................................................................................................................................................ 15
7 Operation..............................................................................................................................................  17
7.1 Extensions with signalling/current measuring module ................................................................................ 17
7.1.1 Menu extension ................................................................................................................................. 17
7.1.2 Additional functions .......................................................................................................................... 17
8 Servicing/Maintenance ........................................................................................................................  28
8.1 Maintenance/inspection measures ................................................................................................................ 28
9 Trouble-shooting..................................................................................................................................  29
10 Related Documents ..............................................................................................................................  30
10.1 Wiring diagram/terminal diagram ................................................................................................................ 30
10.1.1 Individual signals - control board display (example) ....................................................................... 30
10.1.2 Analog output.................................................................................................................................... 30
10.1.3 Three-phase current measurement................................................................................................... 31
10.1.4 Single-phase current measurement .................................................................................................. 32
10.1.5 Field bus connection .......................................................................................................................... 32
10.1.6 Redundant pneumatic level measurement ...................................................................................... 33
10.1.7 Partially redundant bubbler system.................................................................................................. 35
Index .....................................................................................................................................................  37

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 1 General

1 General
This supplementary operating manual accompanies the installation/operating
manual. All information contained in the installation/operating manual must be
observed.

Table 1: Relevant operating manuals

Type series Reference number of the installation/operating
manual
LevelControl Basic 2 4041.80

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 2 Safety

2 Safety

2.1 General
This supplementary operating manual contains additional applicable information.
General installation, operating and maintenance instructions that must be observed
to ensure safe operation and prevent personal injury and damage to property are
given in the installation/operating manual.
The safety information in all sections of this supplementary operating manual and in
the relevant installation/operating manual must be complied with.
The supplementary operating manual must be read and completely understood by
the responsible specialist personnel/operators.
The contents of this supplementary operating manual must be available to the
specialist personnel at the site at all times.
The operator is responsible for ensuring compliance with all local regulations which
are not taken into account in this supplementary operating manual.

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 3 Transport/Temporary Storage/Disposal

3 Transport/Temporary Storage/Disposal

3.1 Condition upon delivery

NOTE
Prior to shipping, the accessories were tested to ensure full compliance with the
specifications. They should, therefore, be in perfect electrical and mechanical
condition upon arrival.
It is recommended that the accessories be inspected for in-transit damage
immediately upon receipt. If there are any complaints or objections, the recipient
and carrier must jointly draw up a damage report.

3.2 Transport

CAUTION
Improper transport
Damage to the accessories!
▷ Always transport the accessories properly and in their original packaging.
▷ During transport, observe the transport instructions on the original packaging.

Transport the accessories as specified.

3.3 Storage
If the ambient conditions for storage are met, the accessories will give reliable service
even after a prolonged period of storage.

Table 2: Ambient conditions for storage

Ambient conditions Value
Relative humidity Max. 85% (no condensation)
Ambient temperature - 10 °C to + 70 °C
▪ Store the accessories in dry, vibration-free conditions and, if possible, in their
original packaging.
▪ Store the accessories in a dry room in which the atmospheric humidity is
maintained at a constant level (as far as this is possible).
▪ Prevent excessive fluctuations in atmospheric humidity (see table "Ambient
conditions for storage").
If stored properly, the accessories will be protected for a maximum of 12 months.

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 4 Description

4 Description

4.1 Compatibility

NOTE
The KSB Service Tool can be downloaded free-of-charge from the KSB web site. The
web site also contains further information on how to order the additional
parameterisation cable required.

Signalling module and current measuring module can be used with device firmware
version 1.2 or higher. Devices with earlier firmware versions must be updated using
the KSB Service Tool.

4.2 General description

Signalling module
The signalling module is an extension module for LevelControl Basic 2.
It features:
▪ Six volt-free signals:
– Fault at pump 1
– Fault at pump 2
– High water
– Sensor fault
– Pump 1 in operation (not available for lifting units with single-phase motor
and cutter)
– Pump 2 in operation (not available for lifting units with single-phase motor
and cutter)
▪ Analog output (level-proportional current signal, type 4–20 mA)
▪ ModBus RTU interface (direct connection or field bus module connection)
▪ System bus interface (currently no function)
▪ Connection option for one current measuring module per pump
▪ Depending on the version, the device is fitted with a pressure sensor for
redundant pneumatic level measurement (without compressor) or for setting up
a partially redundant bubbler system

NOTE
The assignment of the volt-free signals and the measured values provided via the
analog output can be modified using the ServiceTool.

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 4 Description

Fig. 1: Description of signalling module

1 Service interface (for production only - 2 Power supply for PCB (optional, 9–30 V)
parameterisation takes place via the service
interface on the LevelControl Basic 2 printed
circuit board)
3 Current measuring module connection, pump 2 4 Current measuring module connection, pump 1
5 Signalling module connection to LevelControl 6 Analog output (4–20 mA)
Basic 2
7 ModBus-RTU connection 8 system bus connection (no function)
9 Volt-free signal 1 (default: Pump 1 fault) 10 Volt-free signal 2 (default: Pump 2 fault)
11 Volt-free signal 3 (default: High water) 12 Volt-free signal 4 (default: External fault)
13 Volt-free signal 5 (default: Pump 1 in operation) 14 Volt-free signal 6 (default: Pump 2 in operation)
15 Redundant pressure sensor 16 Status LED
17 Terminating resistors for ModBus RTU and system
bus connection

Current measuring module

The current measuring module measures the pump current in the motor power cable
in the control unit.
Up to 10 A, the pump current is measured directly, over 10 A, it is measured via an
upstream current transformer.
The current measuring module is connected to LevelControl Basic 2 via the signalling
module.

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 4 Description

Fig. 2: Description of current measuring module

1 Phase L2 2 Phase L3
3 Connection to signalling module

NOTE
The current measuring module measures the currents in phases L2 and L3 (three-
phase motor) or L (single-phase motor) of the connected pumps.
(ð Section 10.1, Page 30)

4.3 Technical data

Signalling module

Table 3: Technical data

Characteristic Value
Power supply 9–30 V DC
via LevelControl Basic 2
Enclosure BC version: IP00
BS version: IP20
Switching capacity of individual signals 30 V, 1 A
Analog output 0/4-20 mA
Housing version BC version: without housing
BS version: top hat rail housing

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 4 Description

Characteristic Value
Design variants Signalling module
Signalling module with pressure sensor,
3 mlc
Signalling module with pressure sensor,
10 mlc
Weight 0.3 kg

NOTE
The signalling module can be used with device firmware version 1.2 or higher.

Current measuring module

NOTE
LevelControl Basic 2 is only fitted with current measuring module(s) ex works.
Current measuring modules cannot be retrofitted!

The current measuring modules are connected to LevelControl Basic 2 via the
signalling module.
This means that the current measuring module can be used only in combination with
the signalling module!

Table 4: Technical data

Characteristic Value
Power supply Supply via signalling module
Enclosure IP20
Maximum supply voltage 500 V AC
Measuring range 10 (15) A1)
Measuring ranges for indirect 10 to 20 A (30 A)
measurement via transformer 20 to 40 A (60 A)
40 to 75 A (110 A)2)
Weight 0.2 kg

NOTE
The current measuring module can be used with device firmware version 1.2 or
higher.

NOTE
One current measuring module is required for each pump. For dual-pump control,
the signalling module offers connection options for two current measuring
modules.

1) Larger currents can be measured via upstream transformers

2) Measurement of larger currents possible on request

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 5 Installation at Site

5 Installation at Site

5.1 Connecting the signalling module

DANGER
Exposed live parts
Danger of death from electric shock!
▷ Separate the control unit from the power supply before installing the signalling
module.

CAUTION
Improper handling of the control unit and its built-in components
Defective control unit!
▷ Handle the control unit and its built-in components carefully.

CAUTION
Incorrect handling of the rechargeable battery
Electrical damage to the control unit!
▷ If the battery installation option is used, disconnect one of the battery's
connectors before connecting the signalling module. This ensures that the
control unit is completely de-energised.
▷ Do not re-connect the battery connector until the connection has been made.

BC version

Fig. 3: Position of signalling module in BC version

ü The place of installation conforms to the requirements.
1. Separate the control unit from the power supply and verify that it is de-
energised.
2. Open the control unit using a suitable tool.
3. Carefully detach the BC PCB cover plate from the spacers.
4. Connect the signalling module to the BC PCB using the connection cable
supplied.
Make sure the connector is correctly positioned! When attaching the connection
cable, observe the mechanical coding on the connectors!

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 5 Installation at Site

(The connector has a pin that has to engage in the hole in the PCB next to the
PCB-side connector.)

5. Snap the signalling module for the BC version onto the spacers and check that it
is firmly seated.
6. Close the control unit again properly.
7. Reconnect the power supply.
When the device is switched on, the green status LED on the signalling module lights
up continuously. This means that the signalling module is functioning correctly.
If the green status LED on the signalling module does not illuminate, the correct
seating of the cable connecting the signalling module and the LevelControl Basic 2
PCB must be checked again.
If the green status LED on the signalling module flashes, the signalling module has
not been detected by LevelControl Basic 2. In this case, check the firmware version of
the control unit, which is displayed at parameter 4-1-1. Firmware version 1.2 or
higher is required.

NOTE
To set up a redundant pneumatic level measurement system, observe
(ð Section 10.1.6, Page 33) .
To set up a partially redundant bubbler system, observe
(ð Section 10.1.7, Page 35) .

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 5 Installation at Site

BS version

Fig. 4: Position of signalling module in BS version

ü The place of installation conforms to the requirements.
1. Separate the control unit from the power supply and verify that it is de-
energised.
2. Open the control unit.
3. Snap the signalling module for the BS version onto a free top hat rail slot and
check that it is firmly seated.
4. Connect the signalling module to the BS PCB using the connection cable
supplied.
Make sure the connector is correctly positioned! When attaching the connection
cable, observe the mechanical coding on the connectors!
(The connector has a pin that has to engage in the hole in the PCB next to the
PCB-side connector.)
5. Close the control unit again properly.
6. Reconnect the power supply.
When the device is switched on, the green status LED on the signalling module lights
up continuously. This means the signalling module is functioning correctly.
If the green status LED on the signalling module does not illuminate, the correct
seating of the cable connecting the signalling module and the LevelControl Basic 2
PCB must be checked again.
If the green status LED on the signalling module flashes, the signalling module has
not been detected by LevelControl Basic 2. In this case, check the firmware version of
the control unit, which is displayed at parameter 4-1-1. Firmware version 1.2 or
higher is required.

NOTE
To set up a redundant pneumatic level measurement system, observe
(ð Section 10.1.6, Page 33) .
To set up a partially redundant bubbler system, observe
(ð Section 10.1.7, Page 35) .

5.2 Connecting the current measuring module

NOTE
LevelControl Basic 2 is only fitted with current measuring module(s) ex works.
Current measuring modules cannot be retrofitted!

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 5 Installation at Site

Connect the current measuring module in accordance with the wiring diagram.
(ð Section 10.1.3, Page 31) / (ð Section 10.1.4, Page 32)

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 6 Commissioning/Start-up/Shutdown

6 Commissioning/Start-up/Shutdown

6.1 Commissioning/start-up
ü The supplementary operating manual and the installation/operating manual
have been read.
ü The device variant conforms to the requirements.
ü The control unit has been assembled as per operating instructions and connected
to the power supply in accordance with the wiring diagram.
ü The signalling module has been installed as per operating instructions
(ð Section 5.1, Page 11) and connected in accordance with the terminal diagram.
ü The current measuring module has been installed as per operating instructions
and connected in accordance with the terminal diagram.
1. Re-tighten the connection terminals (individual signals, analog output, field bus
connection and current measuring modules).
2. Connect the power cable.
3. Connect the sensors.
4. Insert the motor protection device and fuses.
5. Set the manual-0-automatic switches for both pumps to "0".
6. Switch on the power supply.
7. Check that the green status LED is continuously ON.
8. Check that the parameters are set as required and adapt if necessary.
9. Carry out test run for several start/stop cycles.
10. Check alarm devices, including the individual signals, for proper function.
11. Set the manual-0-automatic switches for both pumps to "Automatic".
ð Both pumps can now be started/stopped by the control unit as required.
12. Provide support and/or training for operating personnel.
13. File a copy of the supplementary operating manual with the installation/
operating manual.

6.2 Shutdown

Short-term shutdown
1. Set the manual-0-automatic switches for both pumps to "0".
ð Both pumps are switched off.
ð The control unit remains operational.

Short-term shutdown for work on the pump

1. Set the manual-0-automatic switches for both pumps to "0".
ð Both pumps are switched off.
ð The control unit remains operational.
2. Open the control unit.
3. For 400V variants:
Switch off motor protection switch for both pumps and secure to prevent
restart.
For 230V variants:
Pull pump mains plug. If the pumps are connected directly to the terminals in
the device, the device must be disconnected from the power supply.
4. Close the control unit again.

Long-term shutdown
1. Set the manual-0-automatic switches for both pumps to "0".
2. Switch off the power supply.

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 6 Commissioning/Start-up/Shutdown

ð This disables all control and signalling functions.

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 7 Operation

7 Operation

7.1 Extensions with signalling/current measuring module

NOTE
Additional parameters available are documented on the enclosed parameter label.

If signalling module and, where applicable, current measuring module are installed,
additional parameters appear in the display. These can be selected as usual using the
arrow keys.
The selectable parameters depend on the operating mode and measurement
method. Only parameters that are relevant to the current operating mode and
measurement method are displayed.

7.1.1 Menu extension

7.1.1.1 Measured values menu

If the signalling module and current measuring module are used, parameters
indicating the current values for each pump are added to the measured values menu.

Table 5: Additional parameters in measured values menu

Parameter Description Single- Dual-
pump pump
station station
1-2-3 Current, pump 1 Current of pump 1 in ampere x -
1-3-3 Current, pump 2 Current of pump 2 in ampere x x

7.1.1.2 Settings menu

If a signalling module with redundant pressure measurement is used, the parameter
indicating the installation height of the second open or closed pressure bell is added
to the settings menu. (ð Section 10.1.6, Page 33)

Table 6: Additional parameter in settings menu

Parameter Description Values
3-4-5-1 Level of bell 2 Distance of the second pressure bell (lower 200 mm (factory setting)
edge) from the bottom of the tank (offset).
Factory setting: 200 mm

7.1.1.3 Signalling module fault

If a fault occurs at the signalling module during operation, this is indicated by fault -
A17 - in the display.

Table 7: Signalling module fault message

Message Description
- A17 - Signalling module fault

7.1.2 Additional functions

7.1.2.1 Volt-free signals

If the signalling module is used, six volt-free signals are provided:
▪ Switching capacity: 30 V, 1 A
▪ Type: Change-over contact.

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 7 Operation

The signal relays are energised in the good or idle state and de-energise in the event
of a signal.

Table 8: Volt-free signals

Volt-free signal Standard assignment Description Signal status
Signal relay 1 Fault pump 1 Pump 1 is blocked due to a fault and de-energised
cannot be started upon demand.
Signal relay 2 Fault pump 2 Pump 2 is blocked due to a fault and de-energised
cannot be started upon demand.
Signal relay 3 High water (A9) The high water switching point has been de-energised
reached
Signal relay 4 Sensor fault (A11) Fault of the level measurement sensors de-energised
used
Signal relay 5 Pump 1 in operation Pump 1 running energised
Signal relay 6 Pump 2 in operation Pump 2 running energised
The state of the signal relays is also indicated by the yellow LEDs positioned above
the relays on the PCB. An illuminated LED indicates an energised relay.

NOTE
In the case of lifting units with single-phase motor and cutter, signal relays 5 and 6
are used to control the start capacitors required for operation and are not available
for volt-free signals.

NOTE
For single-pump systems, the signal relays normally assigned with signals for pump
2 do not carry any standard settings. These can be assigned using the ServiceTool.

The signal relays can be assigned with the following functions using the ServiceTool:

Table 9: Assignment of the signal relay

Signal Description Signal status
Message A1 Motor protection pump 1 (winding protection or motor de-energised
protection switch tripped)
Message A2 Motor protection pump 2 (winding protection or motor de-energised
protection switch tripped)
Message A3 Motor 1 temperature too high de-energised
Message A4 Motor 2 temperature too high de-energised
Message A5 Power failure de-energised
Message A6 Phase error (phase failure) de-energised
Message A7 Leakage at motor 1 de-energised
Message A8 Leakage at motor 2 de-energised
Message A9 High water alert de-energised
Message A10 External alarm de-energised
Message A11 Sensor fault de-energised
Message A12 Incorrect rotary field of mains supply (phase sequence) de-energised
Message A13 Undervoltage (-15 % of rated voltage) de-energised
Message A14 Overvoltage (+15 % of rated voltage) de-energised
Message A15 Flat battery de-energised
Message A16 Service interval (activation via parameter 3-7-1) de-energised
Fault pump 1 Pump 1 is blocked due to a fault and cannot be started upon de-energised
demand.
Fault pump 2 Pump 2 is blocked due to a fault and cannot be started upon de-energised
demand.
Pump 1 operational No fault at pump 1, the manual-0-automatic switch is in "Auto" energised
position

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 7 Operation

Signal Description Signal status

Pump 2 operational No fault at pump 2, the manual-0-automatic switch is in "Auto" energised
position
Pump 1 in operation Pump 1 running energised
Pump 2 in operation Pump 2 running energised
Pump 1 in automatic Manual-0-automatic switch of pump 1 in "Auto" position energised
mode
Pump 2 in automatic Manual-0-automatic switch of pump 2 in "Auto" position energised
mode
Check run pump 1 Check run of pump 1 in progress energised
Check run pump 2 Check run of pump 2 in progress energised

7.1.2.2 Analog output

The signal module offers an analog output with the following specifications:

Table 10: Analog output specifications

Specification Value
Type 0/4–20 mA
External working resistance Mains operation: max. 500 Ω
Battery operation: max. 300 Ω
The analog output signals the measured fill level as standard.
The analog output can optionally be assigned with the following values using the
ServiceTool:

Table 11: Analog output assignment

Parameter Value Display
Level
(ð Section 7.1.2.2.1, Pag
e 19) to
(ð Section 7.1.2.2.4, Pag
e 22)
1-1-3 Mains voltage of the system 0 mA = fault
4 mA ➔ 180 V
20 mA ➔ 500 V
None System current 0 mA = fault
- single-pump: current of pump 1 4 mA ➔ 0 A
- dual-pump: current of pumps 1+2 20 mA ➔ 30 A

NOTE
For current measurement > 10 (15) A, please note the following transformer
factors:
10–20 (40) A: 4 mA ➔ 0 A, 20 mA ➔ 40 A
20–40 (60) A: 4 mA ➔ 0 A, 20 mA ➔ 60 A
40–75 (110) A: 4 mA ➔ 0 A, 20 mA ➔110 A

7.1.2.2.1 Level measurement using float switches or digital sensors

When digital level measuring methods are employed (floats, digital switches), a step
signal corresponding to the switching status is displayed.
The allocation of the switching states is shown in the table below:

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 7 Operation

Table 12: Allocation of switching states for level measurement with float switches or digital sensors
Display Level Analog signal Switching state
When draining When filling
Sensor fault 0 mA - -

Very low 4 mA Pumps OFF Peak load pump ON

Low 7 mA Peak load pump OFF Base load pump ON

(irrelevant)

Medium 10 mA - -

High 13 mA Base load pump ON Peak load pump OFF

(irrelevant)

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 7 Operation

Display Level Analog signal Switching state

When draining When filling
Very high 16 mA Peak load pump ON Pumps OFF

High water 20 mA All pumps ON All pumps OFF

NOTE
If sensor fault and high water are present at the same time, the high water level is
output in accordance with the priority of the pending faults.

7.1.2.2.2 Level measurement using an analog sensor

If a 4–20 mA analog sensor is used for level measurement, the input signal of the
sensor is duplicated.

Fig. 5: Level measurement with analog sensor

1 0 mA = fault
A sensor signal of between 0 and 3.6 mA indicates a broken wire, and sensor fault -
A11- is output.

7.1.2.2.3 Level measurement using a bubbler system or pneumatic measurement

If pneumatic measurement (without compressor) or a bubbler system is used for level
measurement, the analog output provides a level-proportional current signal, i.e. the
measured value is converted into an output current from 4 to 20 mA, depending on
the measuring range of the pressure sensor used in the signalling module.

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 7 Operation

If a control unit with pressure sensor for up to 3 metres of water is used, the fill level
in the range of 0–4 mlc is converted into a signal of 4 to 20 mA.

Fig. 6: Pneumatic measurement up to 3 mlc

1 0 mA = fault
If a control unit with pressure sensor for up to 10 mlc is used, the fill level in the
range of 0–12 mlc is converted into a signal of 4 to 20 mA.

Fig. 7: Pneumatic measurement up to 10 mlc

1 0 mA = fault
If there is a sensor fault, it will always be indicated by 0 mA at the analog output.

7.1.2.2.4 Level measurement for lifting units

On control units for lifting units of the MiniCompacta/Compacta series, the analog
output provides a level-proportional current signal, i.e. the values measured in the
range of 0 to 1 mlc are converted into output currents from 4 to 20 mA, regardless of
any settings made.

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 7 Operation

Fig. 8: Level measurement for lifting units

1 0 mA = fault
If there is a sensor fault, it will always be indicated by 0 mA at the analog output.

7.1.2.2.5 Level measurement using a partially redundant bubbler system or

redundant pneumatic measurement

NOTE
To set up a redundant pneumatic level measurement system or a partially
redundant bubbler system, a signalling module with pressure sensor is required.

NOTE
Redundant arrangement of the sensors enables redundant minimum level
monitoring as stipulated by the Atex directives.

NOTE
If the power supply fails and the unit is operated on battery power, level
measurement will be non-redundant. The redundant pressure sensor is deactivated
during battery operation.

NOTE
To set up a redundant pneumatic level measurement system or a redundant
bubbler system, observe the wiring diagram/terminal diagram.
(ð Section 10.1, Page 30)

The signalling module provides the option of setting up a redundant pneumatic level
measurement system or partially redundant bubbler system.
If a redundant level measurement system is used, the mean value of the two
measured values is used for level measurement and pump control.
In the event of a fault in one of the two level measurement systems,
▪ for non-Atex applications (3-6-1 Atex-Mode = "0", deactivated), the higher of the
measured values is used for controlling the pumps
▪ for Atex applications (3-6-1 Atex-Mode = "1", activated), the higher of the
measured values is used as long as at least one of the two level measurement
systems ensures sufficient submergence of the pump.
If a pump that represents a potential ignition source in a potentially explosive
atmosphere can no longer be guaranteed to be sufficiently submerged, all running
pumps will be stopped.
In the event of a fault, message "A11 – Sensor fault" is output.

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 7 Operation

7.1.2.3 Field bus connection

The extension module for LevelControl Basic 2 offers a Modbus-(RTU) interface which
is galvanically isolated from the control unit.
The ModBus interface can be used directly for integration into a ModBus network
and provides the option of connecting corresponding field bus gateways.
The ModBus interface is implemented as a RS485 interface with ModBus-(RTU)
protocol in accordance with Specification v1.1b.

Table 13: Characteristics of the field bus connection

Characteristic Description/value
Communication protocol Modbus-RTU
Bus terminator 220 Ω (fixed, implemented internally, switchable)
Interface EIA-485 (RS485)
Transmission rate 38400 bit/s (adjustable)
Data bits 8
Parity Even
Stop bits 1
Device type Slave
Bus access Polling between master and slave
Pre-set device address 0xF7 (247)

7.1.2.3.1 Measured values and parameters

Various measured values and parameters are provided as device information via the
field bus system. They can be accessed with function code 03 (read holding registers).
Modbus-RTU only uses 16-bit coils. For values logged as 32-bit numbers, two coils
therefore need to be read out.
To show numerals after the decimal point, the read value is to be moved to the right
by the number of decimal places illustrated under "Type/Format".
Function code, coil and length are shown as hexadecimals and can be transferred
directly to the Modbus-RTU protocol in this format.

Table 14: Measured values and parameters

Function Coil Length Type/Format Parameter Designation Description
code
03 00 01 00 01 16 Bit 1-1-1 Level Displays the level in mm
"signed" (analog) (analog level measurement)
#
03 00 02 00 01 16 Bit 1-1-2 Level Displays the level as status
"signed" (digital) diagram (digital
# measurement)
03 00 03 00 01 16 Bit 1-1-3 Line Voltage Displays the mains voltage in
"signed" volts
#
03 00 04 00 01 16 Bit 1-1-4 Battery Voltage Displays the battery voltage
"signed" in volts
# ,#
03 00 05 00 02 32 Bit 1-1-5 System Operating Operating hours of the
"unsigned" Hours system
#
03 00 07 00 02 32 Bit 1-2-1 Operating Hours Operating hours of pump 1
"unsigned" Pump 1
#
03 00 09 00 02 32 Bit 1-2-2 Start Count Pump 1 Number of start-ups of pump
"unsigned" 1
#
03 00 0b 00 02 32 Bit 1-2-3 Current Pump 1 Current of pump 1
"unsigned"
# ,0

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 7 Operation

Function Coil Length Type/Format Parameter Designation Description

code
03 00 0d 00 02 32 Bit 1-2-4 Effective Power Effective power of pump 1 in
"unsigned" Pump 1 kW
# ,###
03 00 0f 00 02 32 Bit 1-2-5 Power Factor Pump 1 Power factor cos φ of pump 1
"unsigned"
# ,##
03 00 11 00 02 32 Bit 1-3-1 Operating Hours Operating hours of pump 2
"unsigned" Pump 2
#
03 00 13 00 02 32 Bit 1-3-2 Start Count Pump 2 Number of start-ups of pump
"unsigned" 2
#
03 00 15 00 02 32 Bit 1-3-3 Current Pump 2 Current of pump 2
"unsigned"
# ,#
03 00 17 00 02 32 Bit 1-3-4 Effective Power Effective power of pump 2 in
"unsigned" Pump 2 kW
# ,###
03 00 19 00 02 32 Bit 1-3-5 Power Factor Pump 2 Power factor cos φ of pump 2
"unsigned"
# ,##
03 00 1b 00 02 32 bit 2-1-1 Pending Messages Displays all active messages
bit mask
(ð Section 7.
1.2.3.2, Page 25
)
03 00 1d 00 01 32 bit Further messages
bit mask
(ð Section 7.
1.2.3.2, Page 25
)

7.1.2.3.2 Message transfer

Device messages and other messages are transferred as bit masks with a width of 32
bits. Bit 31 is the highest-value bit (left), bit 0 is the lowest-value bit (right). Device
messages are read out via coil "52 1c", all other messages via coil "52 1e".

Table 15: Device messages, coil 52 1c

Bit Code Designation Description
Bit 0 - A1 - Motor protection pump 1 Thermal circuit breaker or motor protection switch
of pump 1 has triggered
Bit 1 - A2 - Motor protection pump 2 Thermal circuit breaker or motor protection switch
of pump 2 has triggered
Bit 2 - A3 - Motor 1 temperature too Motor 1 temperature too high, thermal circuit
high breaker has triggered alert
Bit 3 - A4 - Motor 2 temperature too Motor 2 temperature too high, thermal circuit
high breaker has triggered alert
Bit 4 - A5 - Power failure Power supply has been interrupted
Bit 5 - A6 - Phase error Phase error (phase failure)
Bit 6 - A7 - Leakage at motor 1 Leakage at motor 1 — Leakage sensor has triggered
Bit 7 - A8 - Leakage at motor 2 Leakage at motor 2 — Leakage sensor has triggered
Bit 8 - A9 - High water alert High water alert — tank is full
Bit 9 - A10 - External alarm External alarm – Device at the external input has
been triggered
Bit 10 - A11 - Sensor fault Sensor fault (float switch fault, broken wire, short
circuit)

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 7 Operation

Bit Code Designation Description

Bit 11 - A12 - Incorrect rotary field Incorrect rotary field of mains supply (phase
sequence)
Bit 12 - A13 - Undervoltage Undervoltage (-15 % of rated voltage)
Bit 13 - A14 - Overvoltage Overvoltage (+15 % of rated voltage)
Bit 14 - A15 - Flat battery Flat battery – Device will go into sleep mode soon
Bit 15 - A16 - Service interval system Service interval system, the service interval has
expired, servicing required
Bit 16 - A17 - Signalling module fault A fault has occurred at the signalling module

Table 16: Device messages, coil 52 1e

Bit Code Designation Description
Bit 0 #0 General fault message General fault message relay has switched
Bit 1 #1 Fault pump 1 Pump 1 is blocked due to a fault and cannot be
started upon demand.
Bit 2 #2 Fault pump 2 Pump 2 is blocked due to a fault and cannot be
started upon demand.
Bit 3 #3 Pump 1 operational No fault at Pump 1, the manual-0-automatic selector
switch for Pump 1 is in "Auto" position
Bit 4 #4 Pump 2 operational No fault at pump 2, the manual-0-automatic selector
switch for pump 2 is in "Auto" position
Bit 5 #5 Pump 1 in operation Pump 1 is running
Bit 6 #6 Pump 2 in operation Pump 2 is running
Bit 7 #7 Pump 1 in automatic mode Manual-0-automatic switch of pump 1 in "Auto"
position
Bit 8 #8 Pump 2 in automatic mode Manual-0-automatic switch of pump 2 in "Auto"
position
Bit 9 #9 Check run pump 1 Check run of pump 1 in progress
Bit 10 # 10 Check run pump 2 Check run of pump 2 in progress

7.1.2.3.3 Functions
Various device functions of LevelControl Basic 2 can be executed via field bus. They
can be accessed using function code 05 (Write Single Coil). Function code, coil and
value are shown as hexadecimals and can be transferred directly to the Modbus-RTU
protocol in this format.

Table 17: Field bus functions

Function Coil Value Designation Description
code
05 f5 01 ff 00 Remote Remote acknowledgement of all current fields
acknowledgement
05 f5 02 ff 00 External fault Set/delete the external alarm (A10)
00 00 (Standard setting: both pumps OFF)

7.1.2.3.4 Termination

NOTE
The terminating resistors for ModBus RTU and field bus connection are set at the
factory. If the signalling module is not the end device, remove the terminating
resistors.

If LevelControl Basic 2 is operated as the end device in the field bus system or if a
point-to-point connection with a field bus gateway is made, the terminating resistors
must be set on the PCB in order to guarantee correct operation. This can be achieved
easily via DIL switch S1.

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 7 Operation

Fig. 9: DIL switch S1

Table 18: DIL switch assignment

DIL switch Connection Description Factory
setting
1 ModBus RTU RS485 termination ON
2 RS485 termination ON
3 Galvanically isolated GND (connecting OFF
RS485 GND with common GND)
4 System bus CAN termination ON
5 CAN termination ON
6 Not used OFF

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 8 Servicing/Maintenance

8 Servicing/Maintenance

8.1 Maintenance/inspection measures

KSB recommends regular inspection/maintenance according to the following
schedule:

Table 19: Maintenance/inspection measures

Measure Inspection Maintenance
Read the supplementary operating manual and x x
the installation/operating manual
Check cable connection between signalling x x
module and LevelControl Basic 2 PCB for correct
installation
Check cable connection between current x x
measuring module and signalling module for
correct installation
Re-tighten connection terminals (individual x x
signals, analog output, field bus connection,
current measuring modules)
Check that the green status LED on the signalling x x
module is continuously ON
Check parameters x
Carry out a test run for several start/stop cycles x x
Check alarm devices, including the individual x x
signals, for proper function
Determine the spare parts requirements, if any. x
Provide support and/or training for operating x x
personnel
Supply new installation/operation manual if x x
required

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 9 Trouble-shooting

9 Trouble-shooting
Table 20: Trouble-shooting
Faults Causes Remedy
Control unit showing fault A fault has occurred at the signalling ▪ Check signalling module connection
-A17- module ▪ Switch power supply off and then
back on again
▪ Replace signalling module
Green status LED on signalling Signalling module is not correctly ▪ Check signalling module connection
module not lit connected to the PCB or is defective ▪ Replace signalling module
Green status LED on signalling Signalling module not detected ▪ Check firmware version of the
module flashes control unit and update if necessary
Individual signals are not output Setting and/or connection fault ▪ Check control unit setting
as required ▪ Check signalling module terminal
connection
Analog output delivering a Setting and/or connection fault ▪ Check control unit setting
faulty signal ▪ Check signalling module terminal
connection
Analog output delivering no Setting and/or connection fault ▪ Check control unit setting
signal Level measurement faulty (message ▪ Check signalling module terminal
-A11-) connection
▪ Check level measurement
Faulty behaviour during Setting and/or connection fault ▪ Check control unit setting
pneumatic measurement or Tubing is leaking ▪ Check tubing connections
bubbler control
▪ Check tubing for leakage
Parameters 1-2-3, Current Signalling or current measuring module ▪ Check connections of signalling and
Pump 1, and/or 1-3-3, Current connection fault current measuring module
Pump 2, are not shown or are Current measuring module connections
shown interchanged in the to signalling module interchanged
display
Communication via ModBus RTU Connection fault ▪ Check connection
faulty Communication fault ▪ Check settings
Communication interrupted
▪ Switch power supply off and then
back on again
▪ Reset control unit
Communication with field bus Connection fault ▪ Check connection
system faulty Communication fault ▪ Check settings
Communication interrupted
▪ Switch power supply off and then
back on again
▪ Reset control unit
Incorrect parameter settings Undocumented parameters can also be ▪ Restore parameter settings
after field bus access changed via field bus ▪ Check script for field bus access and
correct

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 10 Related Documents

10 Related Documents

10.1 Wiring diagram/terminal diagram

10.1.1 Individual signals - control board display (example)

Fig. 10: Individual signals - control board display

1 Fault pump 1 2 Fault pump 2
3 High water 4 Sensor fault
5 Pump 1 in operation 6 Pump 2 in operation

NOTE
The assignment of the signal relays can be altered using the service tool.

10.1.2 Analog output

Fig. 11: Analog output

NOTE
The analog output provides a level-proportional 4–20 mA signal. The assignment
can be altered using the service tool.

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 10 Related Documents

10.1.3 Three-phase current measurement

Fig. 12: Three-phase current measurement

1 Power supply to pump 1 2 Power supply to pump 2
3 Pump 1 current measuring module 4 Pump 2 current measuring module
5 Pump 1 current measurement connection to 6 Pump 2 current measurement connection to
signalling module signalling module

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 10 Related Documents

10.1.4 Single-phase current measurement

Fig. 13: Single-phase current measurement

1 Power supply to pump 1 2 Power supply to pump 2
3 Pump 1 current measuring module 4 Pump 2 current measuring module
5 Pump 1 current measurement connection to 6 Pump 2 current measurement connection to
signalling module signalling module

10.1.5 Field bus connection

Fig. 14: Field bus connection

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 10 Related Documents

10.1.6 Redundant pneumatic level measurement

NOTE
The use of a redundant pneumatic system (without compressor) offers redundant
level measurement and also, when ATEX mode is activated, redundant minimum
level monitoring.

Fig. 15: Redundant pneumatic level measurement

1 LevelControl Basic 2 pressure sensor 2 Redundant pressure sensor on
signalling module
3 Reducer 4 Reducer
5 Open or closed pressure bell 6 Redundant open or closed pressure
bell

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 10 Related Documents

To set up a redundant pneumatic measurement system (without compressor), two

sets of closed pressure bells or two sets of open pressure bells are required.
Both closed or open measuring bells must be mounted at a distance of 200 mm
(bottom edge of bell) from the tank floor. If they are installed at a different
installation height, this must be configured in the control unit.

Table 21: Parameter
Parameter Designation
3-4-4-1 Level of bell 1
3-4-5-1 Level of bell 2

NOTE
To relieve the strain on the plug-type connectors in the control unit, run the tubes
of both closed or open measuring bells through cable glands and tighten firmly.

NOTE
To ensure the control unit is functioning correctly, the air supply tubes of both
closed or open measuring bells must be routed with a continuously falling slope to
prevent the formation of water pockets as a result of condensation. Tubes which
are too long must be cut to length during installation.

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 10 Related Documents

10.1.7 Partially redundant bubbler system

NOTE
If the compressor fails due to a fault, both level measurement systems continue to
operate as redundant pneumatic level measurement systems (without compressor).

Fig. 16: Partially redundant bubbler system

1 LevelControl Basic 2 pressure sensor 2 Redundant pressure sensor on
signalling module
3 Compressor for bubbler system 4 Orifice
5 Valve 6 Reducer
7 Y-piece 8 Reducer
9 Open pressure bell 10 Redundant open pressure bell
To set up a redundant pneumatic measurement system (without compressor), two
sets of closed pressure bells or two sets of open pressure bells are required.
A set of two closed or open measuring bells must be mounted at a distance of 200
mm (bottom edge of bell) from the tank floor. If they are installed at a different
installation height, this must be configured in the control unit.

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 10 Related Documents

Table 22: Parameter
Parameter Designation
3-4-4-1 Level of bell 1
3-4-5-1 Level of bell 2

NOTE
To relieve the strain on the plug-type connectors in the control unit, run the tubes
of both closed or open measuring bells through cable glands and tighten firmly.

NOTE
To ensure the control unit is functioning correctly, the air supply tubes of both
closed or open measuring bells must be routed with a continuously falling slope to
prevent the formation of water pockets as a result of condensation. Tubes which
are too long must be cut to length during installation.

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 Index

Index

A
Analog output 19

C
Commissioning/start-up 15

F
Faults 29
Field bus connection 24

I
Individual signals 9
Inspection 28
Installation 11

M
Maintenance 28
Measured values menu 17
Menu extension 17
ModBus 24

R
Redundant level measurement 23, 33

S
Settings menu 17
Shutdown 15
Storage 6

T
Transport 6

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 (01319613)
4041.81_03-EN

KSB SE & Co. KGaA

Johann-Klein-Straße 9 • 67227 Frankenthal (Germany)
Tel. +49 6233 86-0
www.ksb.com

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