INVENTIVE SYSTEMS BA-200 User manual

TECHNICAL MANUAL
FOR
MODEL BA-200
OIL IN WATER ALARM
PART NUMBER: 01-5421-00027
NSN: 6680-01-235-1599
MANUFACTURED BY:
INVENTIVE SYSTEMS INCORPORATED
P.O. BOX 220
21797-C NORTH CORAL DRIVE
LEXINGTON PARK, MARYLAND 20653
U.S.A.
Phone: [phone]
Fax: [phone]
Web: www.oilinwater.org
E-mail: [email protected]
FSCM: 9S280
01 September 1993
Warning
This Product Contains A
Chemical Known to the State of
California to Cause Birth
Defects or Other Reproductive
Harm.

i
MODEL BA-200
OPTIONS CONFIGURATION
Inventive Systems Incorporated,Model BA-200 Oil in Water Content Alarm,has numerous model types
and options that are customer specified. These model types and options are delineated below and those
marked have been installed in your unit.
___ High Temperature Sensor Head (model type BA-200/HT)
___ Explosion Proof Unit (model type BA-200/X)
___ Weatherproof Unit (model type BA-200/WP)
___ 4 to 20 mA Output
___ Navy, 6 hole 150# (10 bar) Flange
___ ANSI B16.5 150# (10 bar) Flange
___ DIN 2576 150# (10 bar) Flange
___ PPM Calibrated Set Point
___ 220-240VAC 50/60Hz Input Power
___ LCD meter
___ Explosion Proof Meter
** RECORD UNIT'S SERIAL NUMBER HERE ___________
(to be completed by user)

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SAFETY SUMMARY
The following are general safety precautions not related to any specific procedures and which therefore
do not appear elsewhere in this publication.
KEEP AWAY FROM POTENTIALLY LIVE CIRCUITS
This equipment derives its power from the 115V or 222V 50/60 Hz AC supply and its signal inputs and
outputs are connected to similarly powered equipments. Malfunctions in this and attached equipments,
including test equipments, may place 115V or 220V AC on signal circuits. Do not assume the safety of
low-voltage DC circuits. Do not assume, but check chassis-to-ground circuit integrity when the chassis is
on the workbench.
DO NOT SERVICE OR ADJUST ALONE
Under no circumstances should any person reach into the chassis for the purpose of servicing or
adjusting the equipment except in the presence of someone capable of rendering aid.
RESUSCITATION
Personnel working on this equipment should be familiar with modern methods of resuscitation.

iii
TABLE OF CONTENTS
Page
1.0 INTRODUCTION 1
1.1 Purpose 1
1.2 Description 1
1.3 Specifications 1
2.0 INSTALLATION 4
2.1 Mechanical 4
2.2 Electrical 4
3.0 GENERAL THEORY OF OPERATION 5
3.1 Principles of Operation 5
4.0 OPERATING INSTRUCTIONS 6
5.0 MAINTENANCE 7
5.1 Preventive Maintenance 7
5.2 Fault Isolation & Trouble Shooting 11
6.0 STORAGE INSTRUCTIONS 15
6.1 Preparation for Shipment 15
7.0 FIGURES 21
LIST OF FIGURES
Figure 1 BA-200 Center of Gravity Page 22
Figure 2 BA-200 Installation Page 23
Figure 3 BA-200 External Wiring Page 24
Figure 4 BA-200 Cross Section of
Sensor Head Page 25
Figure 5 BA-200 Sensor Board Page 26
Figure 6 BA-200 Sensor Board Schematic Page 27
Figure 7 BA-200 Power Wiring Page 29
Figure 8 BA-200 Sensor Head IPB Page 30
Figure 9 BA-200 Frame IPB Page 31
Figure 10 BA-200 Power Supply Card Page 32
Figure 11 BA-200 Installation Page 33
Appendix A CL001 4-20mA Option
REVISION LIST
Date Affected Pages
01 SEP 93 Original
07 SEP 95 iv,v,4,6,9,24,26,29,33
22 OCT 96 i,v,2,3,4,5,14,22,23
06 DEC 96 iii,iv,v,Appendix A
07 JUL 98 Crash recovery
27 AUG 02 I, ii

1.0 INTRODUCTION
1.1 PURPOSE
This manual describes the installation, operation, maintenance and calibration of the Inventive Systems'
model BA-200 OILARM oil in water content alarm.
1.2 DESCRIPTION
The BA-200 OILARM is an instrument that detects and measures the amount of oil in water and
compares the results with a threshold value. This threshold value can be adjusted to any level between 2
and 500 parts per million (PPM) and at such values required by local and international regulations.
Samples are taken at a frequency which complies with marine sampling standards. An alarm relay output
is provided, and activated when the measured oil concentration is higher than the preset value. The
alarm relay output contacts can be used to switch ON or OFF a user supplied auxiliary contactor for
control of valves, pumps, and/or an external alarm event-action circuit. A local visual and audio alarm is
provided as well as a voltage output and a power fail relay output. In addition, many options can be
provided such as extended temperature range, explosion proofing strip charts, meters and 4-20ma
outputs.
1.3 SPECIFICATIONS
MANUFACTURER:
Inventive Systems Incorporated
P.O. Box 220
21797-C North Coral Drive
Lexington Park, Maryland 20653
U.S.A.
PHONE: [phone]
FAX: [phone]
CERTIFICATIONS:
U.S. Coast Guard: 162.050/3013/1
International Maritime Organization: MEPC.60(33)
American Bureau of Shipping: 00NN10170
CALIBRATION SET POINT:
15 Parts Per Million (PPM) or user specified
(refer to page i for the setting of your unit)
CALIBRATION ADJUSTMENT:
2 to 100 PPM (2 TO 500 ppm WITH SPECIAL FACTORY SETUP)
SAMPLE PERIOD:
8.6 Seconds
ACCURACY:
+/- 2 PPM @ 15 PPM
+/- 10 PPM @ 100 PPM
REPEATABILITY:
+/- 2 PPM @ 15 PPM
1

POWER SOURCE:
115VAC +/- 10% (220-240VAC 50/60Hz optional)
60 Hz
1 AMP
SINGLE PHASE
FLOW RATE:
0 to much greater than 50 GAL/MIN (11.4 m3/h)
WEIGHT:
15.1 POUNDS (6.7 kg)
MOUNTING:
150# (10 bar) Navy 6 Hole Flange (standard)
or ANSI B16.5 150# (10 bar) Raised Face Flange
or DIN 2576 150# (10 bar) Flat Faced Flange
ALARM:
Internal Audio Buzzer
Internal Red LED Indicator
ALARM DELAY:
Set at 12 Seconds
Adjustable from 10 to 30 Seconds
ALARM OUTPUT:
SPDT
5 amps @ 120VAC or 1/4 HP (.19 kW)
Voltage Free
OTHER OUTPUTS
SPST Power Fail (N/C)
10 amp @ 120VAC or 1/4 HP (.19kW)
Voltage free
ENVIRONMENTAL:
STORAGE TEMPERATURE LIMITS DEG. F:
MAX: 158oF (70oC) MIN: -40oF (-40oC)
OPERATING TEMPERATURE LIMITS DEG. F:
MAX: 158oF (70oC) MIN: 28oF (0oC) (SAMPLE) 0o(AMBIENT)
MAXIMUM SAMPLE TEMPERATURE DEG. F:
MAX: 240oF (116oC)(High Temperature (HT) Model)
MAX: 158oF (70oC) (all other models)
RELATIVE HUMIDITY AT STORAGE TEMP. %:
MAX: 90 MIN: 0
RELATIVE HUMIDITY AT OPERATING TEMP. %:
MAX: 90 MIN: 0
SHIP MOTION:
ROLL: NO RESTRICTION
2

3
PITCH: NO RESTRICTION
PERMANENT TRIM: NO RESTRICTION
PERMANENT LIST: NO RESTRICTION
PRESSURE:
100 LBS (7 bar) STATIC FOR 5 MINUTES
50 LBS (3.5 bar) OPERATING PRESSURE MAXIMUM
SPECIAL TOOLS & TEST FIXTURES:
NONE provided
NONE required
WEIGHT:
DRY WEIGHT:
15.1 POUNDS (6.7 kg)
WET WEIGHT:
15.1 POUNDS (6.7 kg)
SHIPPING WEIGHT:
17 POUNDS (7.7 kg)
CENTER OF GRAVITY:
REFER TO FIGURE 1
1.4 ITEMS FURNISHED
The BA-200 is furnished with the following items:
- BA-200 OILARM unit
- Technical Manual
- Calibration Certificate
- Coast Guard Certificate
- Warranty.

2.0 INSTALLATION
2.1 MECHANICAL
The BA-200 is installed to a water line by a 2 inch internal diameter tee that is welded or threaded into the
line. Although the BA-200 may be mounted in any orientation, it is suggested that it be mounted
horizontally with the name plate on top. On the tee (Schedule 40 pipe only) is welded a 150-pound (10
bar) Navy, ANSI or DIN flange. The flange is located on the tee so that when the probe body of the BA-
200 is inserted, it will protrude 1/4 to 1/2 inch into the inside diameter of the water line. (Refer to Figure 2
and Figure 11). In the design process, insure that the BA-200 will never sample air and be far enough
down the line so that any air bubbles generated by a pump have time to dissipate. This may mean in
gravity systems the installation of the unit be at a low point in the pipe run or installed in a "trap"
arrangement. Sediment build up will shorten the life of the seals. Insure that the Sensor opening is clear
of any protective covering such as tape. The flanges are then appropriately bolted together. This
completes the mechanical installation.
2.2 ELECTRICAL
* * * * WARNING * * * *
INSURE POWER IS REMOVED FROM ALL WIRING BEFORE ELECTRICAL INSTALLATION IS
ATTEMPTED
* * * * CAUTION * * * *
THIS UNIT CONTAINS STATIC (ESD) SENSITIVE PARTS. OBSERVE PROPER GROUNDING
TECHNIQUES FOR HANDLING OF EQUIPMENT.
The user of the BA-200 must provide a 3/4 inch NPT strain relief that will accommodate their cabling
requirements. The strain relief is inserted into the 3/4" NPT threaded hole in the base plate of the BA-
200. Next refer to Figure 3. With the cover removed, insert the power and external alarm cables through
the strain relief located in the base plate. Route the cables underneath the chassis, around to motor and
locate the connector screw terminal blocks at the rear of the BA-200. Whether using 120 VAC 3 wire or
230 VAC 3 wire, connect the ground (safety, earth) to the ground (#4) screw terminal. If using 120 VAC
50/60 Hz, connect the hot (black) wire to the #6 screw terminal and the neutral (white) wire to the #5
terminal. If using 230 VAC, 50/60 Hz connect the +120 VAC (as measured to ground-safety, earth-) to
the #6 screw terminal. Connect the -120 VAC (as measured to ground-safety, earth-) to the #5 screw
terminal. Tighten all screws. Cabling to the external alarms relay contacts should now be made
according to user requirements to screw terminals NC, NO, and COM (screw terminal 1,2 and 3
respectively). Tighten all screws as required and finally the cable strain relief. The cover should then be
carefully replaced and power applied to the unit. This completes the installation of the BA-200.
The 4-20mA option DOES NOT REQUIRE EXTERNAL POWER. It is self powered; therefore do not
apply 24 or 48 VDC to the 4-20mA leads.
Note: The BA-200 has been calibrated at the factory to you specifications. There is no need to re-
calibrate the unit during pre or post installation. Attempts to re-calibrate the unit may lead to voiding of
the warranty.
4

3.0 GENERAL THEORY OF OPERATION
The BA-200 measures the concentration of oil in water. It is housed in a metal box 8 x 6.5 x 4 inches
(200 x 165 x 100 mm) and attached to a probe body and flange. A mechanical assembly driven by a 7
RPM motor moves samples into and out of a sample chamber. The sample chamber is located in the
probe body and contains a light source, sensor cells and a temperature compensating device. An
electronic printed wiring board and power supply board perform the electro-optic calculation of the
concentration of oil in water. These are the basic elements that measure the concentration of oil in water.
3.1 PRINCIPLES OF OPERATION
Within the sensor probe, light is directed into a chamber filled with a sample. The light is measured by
two photo devices, which transform light into electric current. Refer to Figure 4. One cell, the transmit
photocell, is situated so that light from the sensor's lamp can reach it directly. The second cell, the scatter
photocell, is in the shadow of a light-absorbing pin, the occluding rod. When the sample is clear, that is,
when no oil is present, light from the lamp reaches the transmit cell unimpeded; no light reaches the
scatter cell, which remains in the shadow cast by the occluding rod. When oil is present in the sample,
the light is scattered by oil droplets and reaches the scatter cell. The angle between the transmit cell and
the scatter cell favors the refraction angle for oil and tends to ignore the random scattering of particulate.
As the concentration of oil in water increases, more light is scattered away from the transmit cell to scatter
cell. The amount of oil in water is given by the ratio of scattered light to transmitted light. But since
temperature differences affect photocell response, a temperature compensating Thermistor calibrates this
ratio by correcting for discharge temperature changes. The sensor electronic board converts the
electronic signals from the photocells to a voltage between 0 and 7 volts, which is proportional to the
concentration of oil in water. To insure that the oil in water concentration measured by the probe is the
same as the concentration in the discharge line, the probe piston draws in and ejects a sample from the
sampling probe chamber seven times a minute. The piston, which is driven by a gearmotor turning at 7
RPM, automatically wipes clean the window that covers the sensor lamp and photocells.
5

4.0 OPERATING INSTRUCTIONS
The BA-200 has no operator controls and two indicators, one audio and one visual. If the set point for the
oil in water concentration is exceeded, a pulsating buzzer is sounded and a red indicator light is lit. The
red indicator light can be observed at the back of the unit, a few inches above the knurled nut that holds
the cover in place. External alarms and indicators are the responsibility of the user.
To increase the life of the BA-200, the unit should not be run dry for extended periods of time.
Another way to extend the life of the unit is to slave the BA-200 to the pump or whatever is driving
the water through the line. Also refer to precautions outlined in section 2.0, Installation.
There are no special power-up or power-down procedures or sequences.
The 4-20mA option DOES NOT REQUIRE EXTERNAL POWER. It is self powered, therefore do not
apply 24 or 48 VDC to the 4-20mA leads.
6