Character string buffer too small problem

hi, guys:
I have a question that may be silly, I got error "ORA-06502: PL/SQL: numeric or value error: character string buffer too small" when I run a query. if I uncomment "and rox.status='Active'" condition, I do not have the error. I guess it is related to some specific rows. I checked online, it looks the length of some varchar2 variable is not enough, but I just cannot find cause. I also notice there might be an error about v_level in the function, I should use number instead of varchar2 type. but after I changed the type of v_level, the error is still there. I would be cautious as this is a legacy system. Could anyone help me on this problem?
I have a query like this:
select *
from registration_offender_xref rox
where SOR_OFFENDER_DETAILS.get_offender_level(rox.offender_ID)=3
--and rox.status='Active'
and rox.end_registration_date is not null;I get error message as :
ORA-06502: PL/SQL: numeric or value error: character string buffer too small
ORA-06512: at "SORS.SOR_OFFENDER_DETAILS", line 124
06502. 00000 - "PL/SQL: numeric or value error%s"
SOR_OFFENDER_DETAILS.get_offender_level return a number value from 1 to 3, or a null value. Here is the code
  function get_offender_level(p_offender_id IN NUMBER) return NUMBER as
      sex_offender_flag number;
      tier_level number;
      override_num number;
      v_status  varchar2(10);
      v_aggravated  varchar2(10);
      v_habitual  varchar2(10);
      v_level  varchar2(10);
      cursor tierNum is  -- as May 22, 2008 per HKT of DOC (past portal code), Level/Tier is displayed for all offenders
               select max(c.tier)
      from sor_offense o, sor_offense_code c
               where o.offender_id = p_offender_id
               and o.OFFENSE_CODE = c.CODE_ID
      and upper(o.status) = 'ACTIVE';
  begin
      select count(*)
      into sex_offender_flag
      from registration_offender_xref rox
      where rox.offender_ID=p_offender_id
      and reg_type_ID=1;
      if sex_offender_flag>0 then
          OPEN tierNum;
          FETCH tierNum INTO v_level;
            if tierNum%NOTFOUND then
            tier_level := null;
            end if;
          CLOSE tierNum;
          select tier_overRide into overRide_Num
          from registration_offender_xref
          where offender_id = p_offender_id
          and reg_type_id = 1;
          if overRide_Num is not null then
            v_level:=overRide_Num;
          end if;
          --dbms_output.put_line('overRide_Num:'||overRide_Num);   
          --dbms_output.put_line('after override:'||p_level);
/*error line*/        
            select status,  decode(aggravated,'Y','Yes','No') aggravated,
           decode(habitual,'Y','Yes','No') habitual
          into v_status,  v_aggravated, v_habitual
          from registration_offender_xref
          where offender_id = p_offender_id
          and reg_type_id = 1;
            if upper(v_status) in ('COMPLETED', 'DECEASED', 'DELETED') then
               v_level := null;
            end if;
           --dbms_output.put_line('before final:'||p_level);
            if v_aggravated = 'Yes' or v_habitual = 'Yes' or v_level = 3 then
               v_level := 3;
            end if;
           --dbms_output.put_line('final:'||p_level);
            if override_num is not null then
               v_level := overRide_Num;
            end if;   
               else
            v_level:=null;
      end if;
      return v_level;
  end get_offender_level;Thanks a lot!
Sam
Edited by: lxiscas on May 23, 2013 8:38 AM
Edited by: lxiscas on May 23, 2013 8:41 AM
Edited by: lxiscas on May 23, 2013 9:01 AM

I'm not suggesting this is your problem, but
select status
into v_status,
from registration_offender_xref But you have declared
      v_status  varchar2(10);Much better to declare things like this
      v_status  registration_offender_xref.status%type;That way you know your variable is declared with a proper length, if the column length ever changes ... your code doesn't go kaboom.
Cheers,

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    I'm not suggesting this is your problem, but
    select status
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    One more confirmation from you guys please, I have also suggested them to upgrate the environment to the latest version, hoping this will resolve the issue, please confirm?
    In the latest version also we have same size (32KB) limit or it has been increased?
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