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Surefire BMS-350 Installation And Operation Manual

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BMS-350
Installation and
Operations Manual

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Summary of Contents for Surefire BMS-350

  • Page 1 Proudly Made in the USA BMS-350 Installation and Operations Manual...
  • Page 2 The BMS-350 monitors the target temperatures with either an RTD or Thermocouple, which indicates temper- atures (RTD) 0°F to 670°F or (Thermocouple) 32° F to 2700° F. The BMS-350 controls both the pilot and main burner gas valves as required, and is designed as a fail safe system. The system also contains high tem- perature shutdown, flame failure shutdown, along with a an audible startup warning.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS   Certifications and Warnings Warranty Statement BMS-350 Description Enclosure Circuit Board LED Indicators Graphic Overlay Keypad Functions Component Descriptions SureFire Ignition Units 10-11 Additional Components 12-13 Installation Guide 14-17 Installation Wiring Diagram Fuel Train Diagrams Controller Setup 20-25 Operation Guide...

  • Page 4: Certifications And Warnings

    CERTIFICATIONS AND WARNINGS   ETL Certified to the Following Standards: Certified To: Conforms To: CSA STD C22.2 No. 61010 -1 UL STD 61010 –1 CSA STD C22.2 #213 ISA STD 12.12.01 7.8 amps @ 12.0 VDC MAX 0.025 amps @ 12.0 VDC AVG WARNING - EXPLOSION HAZARD –...

  • Page 5: Warranty Statement

    SureFire shall not be liable for any loss, cost or damages, of any kind whatsoev- er, whether consequential, indirect, special or otherwise, arising out of or in connection with the equipment or any defect therein, even if caused by the negligence of SureFire, its employees or agents.

  • Page 6: Bms-350 Description

      Enclosure The SureFire BMS-350 system uses a polycarbonate NEMA 4X Enclosure to house the circuit board. The Graphic overlay with a membrane keypad is mounted on the exterior of the enclosure. The NEMA 4X enclosure provides a high level of protection from harsh outdoor elements: ...

  • Page 7: Circuit Board

    BMS‐350 DESCRIPTION BMS-350 Circuit Board The SureFire BMS-350 system is controlled by a state of the art, non-arcing electronics that monitor and control all burner functions. It comes with 4 LED indictors and a status code LED display. It contains in-...

  • Page 8: Led Indicators

    BMS‐350 DESCRIPTION   LED Indicators The circuit board LEDs illuminate through the lid of the enclosure. The LEDs indicate the following: LED Indicator Status LED ON - Indicates that the system is on and operating properly GREEN Blinking - Indicates a standby interlock is activated LED ON - Indicates that the system is off Blinking - Indicates a shutdown failure or interlock has been activated LED ON - Indicates the igniter is on...

  • Page 9: Keypad Functions

    BMS‐350 DESCRIPTION   Keypad Functions The SureFire BMS-350 has a 16 button keypad to assist in controlling and monitoring the system. Button Functions Increases the current value Primary Up Arrow Press & hold for 5 seconds to unlock the system - A series of zeros will appear on the display screen...

  • Page 10: Surefire Ignition Units

    COMPONENT DESCRIPTION   SureFire FT-Series Ignition Units The SureFire BMS-350 is compatible with most FT series igniters. Each unit is designed for specific applications. Piloted System FT-1 System are designed for long life in burner applications as a pilot. The FT-1 series offers flame sensing through flame rod or thermocouple.
  • Page 11 500,000 btu/H FT-6 Systems are suitable for pilotless 3” burner  applications, rated at 1,000,000 btu/H NOTE: Please consult local SureFire Field Tech Support for proper pilot placement and proper ori- fice sizing selection. FT-4-AF (above) and FT-6-AF (below): These two unit are utilizing a Flame Rod as a flame sensing mechanism.

  • Page 12: Component Descriptions

    COMPONENT DESCRIPTIONS   12 Volt SureFire Actuator  The 12V SureFire actuator is designed to control the main fuel gas to the main burner  No adjustment necessary! The actuator is factory pro- grammed and pre-wired  1” NPT X 1” NPT connection, full port ...
  • Page 13 1/2” NPTX 1/2” NPT connection  Available in the following sizes: 6” and 9”.  Please Contact SureFire for appropriate product part number. Slow Flow Valve Reduces the inrush of fuel gas into the diaphragm valve  for smooth and reliable ignition.

  • Page 14: Installation Guide

    Valve terminals (1, 2 and 3) NOTE: Actuator 1 terminate @ SureFire 1 Actuator 2 terminate @ SureFire 2 Actuator 3 terminate @ SureFire 3 NOTE: Must use SureFire Actuator valve or an actuator approved by SureFire. PLC/ Scada Connection 1.
  • Page 15 4-20mA The proper connection method for the 4-20mA remote circuit monitoring is as follows 1. Ensure there is no power to the BMS-350 or PLC before con- necting the wires. RTD Scaling: 4 mA = 0 °F 20 mA= 670 °F 2.
  • Page 16 INSTALLATION GUIDE   Thermocouple Installation 1. If using a thermocouple for temperature control, make the connection from the positive lead of the thermocouple (yellow) to the positive terminal, (Port 13) and the negative lead of the thermocouple (red) to the negative terminal (Port 14). 2.
  • Page 17 INSTALLATION GUIDE   Battery Installation 1. Install a 12 VDC SLA battery within an enclosure separate of the BMS-350 enclosure 2. Make the connection from the negative side of the battery to the negative terminal (Port 34) NOTE: 3. Make the connection from the positive side of the battery to the...

  • Page 18: Installation Wiring Diagram

    INSTALLATION WIRING DIAGRAM...

  • Page 19: Fuel Train Diagrams

    FUEL TRAIN DIAGRAMS   Pilotless Fuel Train Piloted Fuel Train...

  • Page 20: Controller Setup

    TC = 1300°F High temp range RTD = 32°F — 588°F TC = 32°F — 2398°F NOTE: The SureFire System comes standard with a built in minimum 2° F temperature span to prevent undue wear associated with equipment short cycling.
  • Page 21 CONTROLLER SETUP   Flame Sense (F/H) The Flame Sense button displays the current flame sensing device.  To set or change the flame sensor, follow these steps:  1. Unlock the system by pressing and holding the up arrow button for 5 seconds until a series of zeros appear.
  • Page 22 CONTROLLER SETUP   Extreme High Temp Delta (EHTD) The EHTD button displays the current Extreme High Temp Delta setting.  To set or change the EHTD, follow these steps:  1. Press the EHTD button to view the current delta setting 2.
  • Page 23 CONTROLLER SETUP   Pilot Mode (1/2) The Pilot Mode 1/2 button displays the current pilot mode.  The system has two pilot mode option when used in a piloted application, Intermittent or Standing Pilot  To set or change the Pilot Mode option, please follow these steps: ...
  • Page 24 CONTROLLER SETUP   Solenoid Timing The Solenoid Timing button displays the current timing between the first stage solenoid opening and the  second stage solenoid opening. To set or change the solenoid timing, follow these steps:  1. Press the Solenoid Timing button to view the current timing. 2.
  • Page 25  Power Supply The SureFire controller accepts rated voltages as described in the specification, page 34. No setup is required. However, the system does have a built-in volt meter to measure battery voltage at all times. To check the bat- tery volts, press the battery volts button.

  • Page 26: Operation Guide

    OPERATIONS GUIDE Status Codes Run Codes Description System running, no errors Waiting for startup signal Pre-purge on Startup Purge between Ignition Attempts Waiting for stage 2 solenoid valve to open Standby Codes Description Standby Interloop Loss of Fuel Gas Shutdown Error Codes Description Manual Shut Off Max Retries Exceeded Low Battery Volts...

  • Page 27: Operation Guide

    OPERATIONS GUIDE Operational Situations Green Operational State Alarm Run Status Red LED Blue LED Amber LED System OFF or Manual Open Open Shutdown System ON, Pre-purge Close Open complete, Igniter On Flame sensed, Burner run- Close Close ning No Errors Shutdown, Igniter Error Open Open Blinking...

  • Page 28: Operation / Flow Chart: Piloted And Pilotless System

    INTERMITTENT PILOT OPERATION Ignition Process - Intermittent Pilot 1) Unlock system 2) Set desired parameters 3) Press the ON button 4) Pre-purge on Start-up- 60 second countdown displayed - Green LED ON 5) Audible Alarm - 5 second countdown displayed - Green LED ON 6) Igniter - 8 second countdown displayed - Green and Amber LED ON 7) Stage 1 Solenoid/Actuator valve opens - igniter remains on - Green and Amber LED ON 8) Ignition is achieved, flame is sensed - Green and Blue LED ON...
  • Page 29 INTERMITTENT PILOT OPERATION Flow Chart...
  • Page 30 STANDING PILOT OPERATION Ignition Process - Standing Pilot 1) Unlock system 2) Set desired parameters 3) Press the ON button 4) Pre-purge - 60 second countdown displayed - Green LED ON 5) Audible Alarm - 5 second countdown displayed - Green LED ON 6) Igniter - 8 second countdown displayed - Green and Amber LED ON 7) Stage 1 Solenoid/Actuator valve opens - igniter remains on - Green and Amber LED ON 8) Ignition is achieved, flame is sensed - Green and Blue LED ON...
  • Page 31 STANDING PILOT OPERATION Flow Chart...
  • Page 32 PILOTLESS OPERATION Ignition Process - Pilotless 1) Unlock system 2) Set desired parameters 3) Press the ON button 4) Pre-purge - 60 second countdown displayed - Green LED ON 5) Audible Alarm - 5 second countdown displayed - Green LED ON 6) Igniter - 8 second countdown displayed - Green and Amber LED ON 7) Stage 1 Solenoid/Actuator valve opens - igniter remains on - Green, Blue, and Amber LED ON 8) Ignition is achieved, flame is sensed - Green and Blue LED ON...
  • Page 33 PILOTLESS OPERATION Flow Chart...

  • Page 34: Specifications

    SPECIFICATIONS   Power Supply Specifications Device Specification Battery 12 VDC - 14.5 VDC 12 VDC Power Supply Set @ 13.4 VDC Solar Panel 12.0 VDC Only — 75 Watt MAX 24VDC Input 24.0VDC Ignition Unit Specifications Ignition Unit @ Max 6.0 Amps Ignition Unit @ Steady state 1.5 Amps —...

  • Page 35: Troubleshooting Guide

    TROUBLESHOOTING GUIDE   RUN CODES Code Symptom Action Visual Pilot/Main burner is 1. Normal operation Green & Blue LED  2. Process getting up to System Running No errors are present. temperature  Pilot/Main burner not 1. Normal operation. Green LED ON. ...
  • Page 36 TROUBLESHOOTING GUIDE   STANDBY CODES Code Symptom Action Visual Pilot/Main burner not 1. System detecting an open Blinking Green LED.  running. circuit. Standby Interloop No activity when 2. Customer supplied switch is  attempting startup. activated. Ports 20 and 21 have 3.
  • Page 37 TROUBLESHOOTING GUIDE   SHUTDOWN CODES Code Symptom Action Visual Pilot/Main burner 1. System has been turned OFF Red LED ON.  not running. Manually. Manual Shut Off 2. System has been turned OFF remotely by a momentary switch signal to the Remote OFF terminal, ports 15 &...
  • Page 38 4. Verify flame rod and/or flame rod wire is not contacting ground. 5. Verify circuit board is not ex- posed to moisture. 6. Flame rod sensor failure, contact SureFire Tech for support. Pilot/Main burner 1. System detecting a disconnect Blinking Red LED ...
  • Page 39 TROUBLESHOOTING GUIDE   SHUTDOWN CODES Cont. Code Symptom Action Visual Pilot/Main burner 1. Process temperature has exceed EHTD Blinking Red LED  not running. setting. Extreme High No activity when 2. Inspect for leaking control valves.  Temp attempting startup. 3. Solenoid valve not closing. Pilot/Main burner 1.

  • Page 40: Troubleshooting Guide

    TROUBLESHOOTING GUIDE   SHUTDOWN CODES Cont. Code Symptom Action Visual Pilot/Main burner 1. System detecting a disconnect upon Blinking Red LED.  not running. initial start-up. Stage 1 solenoid No activity when 2. Check device for faulty operation.  valve attempting startup. 3.

  • Page 41: Modbus Information

    The Modbus registers, their contents, command sequencing and examples of command exe- cution over Modbus are described. This document applies to firmware revisions 1.9. In order to use Modbus 1.9, the BMS-350 must be upgraded to firmware package 2.6.
  • Page 42 Modbus Function 6 (write single register) or Modbus Function 16 (write multiple registers). The sup- plied data will be written to the specified register. The following table is the register map for the BMS-350. Bits are in MSB first order. Modbus...
  • Page 43 MODBUS INFORMATION   Modbus Register name Data type Notes address Modbus master does R (Read) or RW (Read or Write) 40005 Configuration and sta- unsigned int Bit 0 – Light status tus(R) 0 : RED light is on solid 1 : GREEN light is on solid Bit 1 –...
  • Page 44 MODBUS INFORMATION   Modbus Register name Data type Notes address Modbus master does R (Read) or RW (Read or Write) 40009 Number of successes unsigned int Rolls over at 9999 40010 Command status(R) unsigned int 0x55 IDLE - Ready for new command 0x01 Command executed OK 0x02 Bad command, nothing done 0x03 BMS read of exec reg from Modbus board...
  • Page 45 MODBUS INFORMATION   Modbus Register name Data type Notes address Modbus master does R (Read) or RW (Read or Write) 40013 Command execute unsigned int Set to non-zero to request that the command in regis- (RW) ter 40011 be executed with the parameter in register 40012(if needed).
  • Page 46 MODBUS INFORMATION   Modbus Register name Data type Notes address Modbus master does R (Read) or RW (Read or Write) 40028 Bit 8 – Spare standby unsigned int Bit #8 of register 40005 unpacked into a single regis- ter for use by controllers with primitive bit manipula- 0 : Clear tion capabilities.
  • Page 47 MODBUS INFORMATION   Modbus Register name Data type Notes address Modbus master does R (Read) or RW (Read or Write) 40037 Safety T/C Tempera- unsigned int Bit 9..0 is 0-2400 degrees (Thermocouple) ture 40038 Safety T/C Tempera- unsigned int Bit 9..0 is 0-2400 degrees (Thermocouple) ture Threshold 40039 Unallocated...
  • Page 48   4.0 Command operation Command operation on the BMS-350 utilizes the “mailbox” concept. The general sequence is as follows: 1. MASTER reads Command Status register (Modbus 40010). If it reads as 0x55 (IDLE) then proceed. Otherwise wait a short time (a few hundred ms would be reasonable) and poll that register again. Contin- ue to do so until the register reads as 0x55 (IDLE).
  • Page 49 In the following example the Modbus master attempts to change the high temperature limit and then turn ON the BMS-350. The attempt to change the high temperature limit fails initially because the BMS-350 had not been unlocked. After the BMS-350 is unlocked, the temperature limit is changed and the unit is turned ON. Time...
  • Page 50 Sees command exec register with 40010 (status) 0x01 non-zero value. Reads command. 40011 (cmd) 0x01 Attempts to execute command. 40012 (param) 0x7D Succeeds in unlocking BMS-350 40013 (exec) 0x01 Writes OK code to command status reg. Polls command status register. 40010 (status) 0x01 Sees OK (0x01).
  • Page 51 MODBUS INFORMATION   Time Master's action BMS-350 action Registers step Request command execute by 40010 (status) 0x55 writing 0x01 to command exec 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x01 Sees command exec register with 40010 (status) 0x01 non-zero value. Reads command 40011 (cmd) 0x03 and parameter.
  • Page 52 MODBUS INFORMATION   Time Master's action BMS-350 action Registers step Polls command status register. 40010 (status) 0x01 Sees OK (0x01). Proceeds to 40011 (cmd) 0x04 next step. 40012 (param) 0x7D 40013 (exec) 0x01 Write 0x00 to command exec 40010 (status) 0x01 reg.
  • Page 53 MODBUS INFORMATION   The following table shows the switch settings for SW1-1 through SW1-5 required to obtain the desired Mod- bus address: Desired Mod- SW1-1 SW1-2 SW1-3 SW1-4 SW1-5 bus address...
  • Page 54 DISCUSSION: Due to the hardware constraints on the BMS-350, the LED display will flicker slightly during normal operation when the Modbus is in use. If the Modbus master polls the BMS-350 for data at a rapid rate, or transfers many registers during each poll, the flickering becomes worse. If the Modbus is being queried on a continuous basis, the display and keypad may become difficult to operate.

  • Page 55: Software Versions

    SOFTWARE VERSIONS   BMS-350 Software Version Release Date Description V2.5 5/8/2019 Standard base software MODBUS Software Name Release Date Description Standard base software Modbus 350 5/6/2019 (Read / Write)

  • Page 56: Contact Information And Manual Version

    BMS-350 Installation and Operations Manual 10/19/2016 Last Update: 05/08/2019 Version 5.0 SureFire Farmington, NM Office: 1910 Rustic Place, Farmington, NM 87401 P: 505-333-2878 F: 505-333-2879 SureFire Houston, TX Office: 12510 Cutten Rd. Houston, TX 77066 P: 281-377-9756 F: 281-379-1081 Tech Support:...

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