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Surefire BMS-300 Installation & Operation Manual

Iburner management systems
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INSTALLATION & OPERATIONS
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PROUDLY MADE IN THE USA

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Summary of Contents for Surefire BMS-300

  • Page 1 INSTALLATION & OPERATIONS MANUAL PROUDLY MADE IN THE USA...
  • Page 2 INTRODUCTION The BMS-300 is designed for heavy duty oilfield applications and is certified to UL and ISA standards for hazardous areas. The BMS-300 is designed to operate with the FT Ignition units, to provide optimal ignition. The controller’s display is designed to operate in ambient temperature from –40°F to 131°F, and is coated for corrosion resistance.

  • Page 3: Table Of Contents

    12-13 Installation Guide 14-19 Installation Wiring Diagram Fuel Train Diagram Controller Setup 22-29 Operation Guide 30-31 Operation / Flow Chart: Piloted and Pilotless System 32-37 Specifications Basic Troubleshooting 39-43 Modbus Information 44-52 BMS-300 Software Versions Contact Information & Manual Version...

  • Page 4: Certifications And Warnings

    CERTIFICATIONS AND WARNINGS Suitable for use in Class I, Division 2, Groups C, D, T6 Hazardous Operation - 40°C ( - 40°F ) ≤ (Classified) and Ordinary Location Amb. Temp ≤ 55 °C ( 131°F ) CERTIFIED TO: CONFORMS TO: CSA STD C22.2 NO. 61010-1 UL STD 61010-1 CSA STD C22.2 NO.

  • Page 5: Warranty Statement

    WARRANTY Warranty Statement SureFire warrants all equipment of its own manufacture to be free of defects in material and workmanship for a period of twenty-four (24) months from the date of manufacture. SureFire’s sole obligation hereunder shall be expressly limited to repair or exchange free of charge, F.O.B.

  • Page 6: Bms-300 Description

    BMS‐300 DESCRIPTION Enclosure The SureFire BMS-300 System uses a polycarbonate NEMA 4X enclosure to house the circuit board. The graphic overlay with membrane keypad is mounted on the exterior enclosure. The NEMA 4X enclosure provides a high level of protection from harsh outdoor elements: ...

  • Page 7: Circuit Board

    BMS‐300 DESCRIPTION BMS-300 Circuit Board The SureFire BMS-300 System is controlled by state of the art non-arcing electronics that monitor and control all burner functions. It comes with 4 LED indicators and a Status Code LED Display. It also comes with individual terminal blocks, ground lug, and power connector to ease wiring and installation.

  • Page 8: Led Indicators

    BMS‐300 DESCRIPTION LED Indicators The circuit boards 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 igniter is on.

  • Page 9: Keypad Functions

    BMS‐300 DESCRIPTION 16 Button Keypad The SureFire BMS-300 System has a 16 Button Key Pad to control and monitor the system. The buttons perform the following functions: BUTTON FUNCTION - DISPLAY Up Arrow -Increases the current value. Press & hold with the Hours On button for 5 seconds to unlock unit...

  • Page 10: Component Description

    Armored wiring harness to 500°F duty / 800°F flash  Direct termination to BMS-300 controller  FT-1-S: The unit above is utilizing the Igniter as a flame sensor. NOTE: Please consult local SureFire Field Tech Support for proper pilot placement and flame sensing selection.
  • Page 11 FT-4-AF (above) and FT-6-AF (below): Alternate termination to BMS-300 controller  These two units are utilizing a Flame Rod as a flame sensor. NOTE: Please consult local SureFire Field Tech Support for proper pilotless ignition unit and orifice siz- ing selection.

  • Page 12: Additional Components

     Simple termination and installation.  Kalrez elastomer plunger.  Plunger replacement kits available.  Applications include– non-venting pilotless fuel trains, double block fuel trains, fuel trains for combustors and flares systems. Please Contact SureFire for appropriate product part number.
  • Page 13 Reduces the inrush of fuel gas into the diaphragm  valve for smooth and reliable ignition. Required on all pilotless installations when not  using an actuator valve. Recommended for piloted installations too.  Please Contact SureFire for appropriate product part number.

  • Page 14: Installation Guide

    Any damage caused by standing on or using the enclosure as a step is NOT covered under warranty.  SureFire Actuator Valve Installation 1. Install the SureFire Actuator Valve in the fuel train for the main burner line. 2. Terminate wires at terminal block labeled Actuator Valve (1, 2, and 3) from the SureFire Actuator Valve terminals (1, 2 and 3), See note below.
  • 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-300 or PLC before terminating any wires. 2. Connect the positive wire from the remote monitoring equipment to port 5 and the negative wire to port 4.
  • Page 16 4. Cut and bend custom 3/8” tubing and connect to tubing fittings on solenoids. 5. Use proper connectors and conduit for wiring. 6. Terminate solenoid wires to the SureFire controller. For piloted application use stage 1 & stage 2 solenoid terminals NOTE: See page 21 for solenoid location on fuel train for piloted and pilotless application.
  • Page 17 INSTALLATION GUIDE Standby 1. Install a normally open or normally close dry contact device in one of the assigned terminal (Ports 17-18, 23-24 & 27-28) 2. If no device is used, a jumper needs to be in place at the assigned terminal. NOTE: Closed Contact = Normal Operation Open Contact = Failed Operation NOTE: Standby does not require a local reset to re-start...
  • Page 18 Terminate to ports 31 & 32. Flame sensing switch needs to be on Igniter.  NOTE: Reference fig. 1 on page 23 for flame sensing switch. For proper FT unit positioning, contact tech support @ 505-333-2876 or the local SureFire representative...
  • Page 19 2. Connect negative (-) terminal to port 35 3. Connect positive (+) terminal to port 36 NOTES:  If battery is more than 10 feet away from SureFire controller, use larger wire as needed.  If utilizing 12 VDC power supply, set voltage @ 13.4...

  • Page 20: Installation Wiring Diagram

    INSTALLATION WIRING DIAGRAM...

  • Page 21: Fuel Train Diagram

    FUEL TRAINS Pilotless Fuel Train Piloted Fuel Train...

  • Page 22: Controller Setup

    NOTE: Low temperature factory setting is 60°F / 15°C Low temperature set points: 10°F — 486°F / -12°C — 250°C NOTE: The SureFire System comes standard with a built in minimum 4°F temperature span to prevent undue wear associated with equipment short cycling.
  • Page 23 CONTROLLER SETUP Flame Sensor The Flame Sensor button displays the current flame sensing de-  vice. To set or change the flame sensor, follow these steps:  1. Position the flame sensing switch to desired setting: Flame Rod or Igniter. See Fig. 1 2.
  • Page 24 CONTROLLER SETUP FSV / Solenoid Timing Primary Function: The FSV button displays the current flame strength valve for the Flame Rod and Igniter.  To check flame strength when using a Flame Rod:  1. Press the FSV button. When no flame is present, the value will be above 500. ...
  • Page 25 Deteriorating Igniter Flame strength = 10 Flame strength = 15 Threshold setting = 3 Threshold setting = 3 Threshold = 13 Threshold = 18 For proper Flame Senor Threshold selection, contact tech support @ 505-333-2876 Or the local SureFire representative...
  • Page 26 CONTROLLER SETUP RTD/PS The RTD/PS button displays the current input control device.  The system can be controlled by two different input devices: RTD or ALT SENSE INPUT.  To set or change the input device, use the following steps:  1.
  • Page 27 CONTROLLER SETUP A/S (Attempts and Successes) / FPT (Flame Proof Timing) Primary Function: The A/S button displays Ignition Attempts and Successful Ignitions.  The unit has a built in counter to record the number of Ignition Attempts (A) and Successful Ignitions (S). ...
  • Page 28 CONTROLLER SETUP Status Code / Pilot Mode Primary Function: The Status Code button displays the current code that corresponds with current unit status.  To observe the status of the system, press the status code button to view the current code. Reference the ...
  • Page 29 The EHTD is settable between 10°F — 100°F above the high temperature setting Power Supply The SureFire controller accepts rated voltages as described in the specifications, page 38. No setup is re-  quired. However, the system does have a built-in volt meter to measure battery voltage at all times. To check the battery volts, press the battery volts button.

  • Page 30: Operation Guide

    OPERATION GUIDE Status Code Run Codes Description System Running Pre-Purge on Startup Waiting for startup signal Purge between Ignition Attempts Waiting for main valve to open Standby Codes Description Standby Interlock Spare Standby 1 Spare Standby 2 Shutdown Codes Description Manual / Remote Shut Off Max Retries Exceeded Low Battery Volts Igniter Short Circuit...
  • Page 31 OPERATION GUIDE Operational Situations Operational State Status Red LED Green LED Blue LED Amber LED System OFF or Manual Open Shutdown System ON, Pre-purge com- Open plete, igniter on Flame sensed, Burner run- Close ning, No Errors Shutdown, Igniter Error Open Blinking Blinking Standby Error Open...

  • Page 32: Operation / Flow Chart: Piloted And Pilotless System

    INTERMITTENT PILOT OPERATION Ignition Process 1) Unlock system. 2) Set desired parameters. 3) Press the ON button. 4) Pre-purge - 120 second countdown displayed - Red LED ON. 5) Audible Alarm - 5 second countdown- Green LED ON. 6) Igniter on - 5 second countdown - Green and Amber LED ON. 7) Stage 1 Solenoid valve opens - igniter unit remains on - Green, Blue and Amber LED ON.
  • Page 33 INTERMITTENT PILOT OPERATION Flow Chart...
  • Page 34 STANDING PILOT OPERATION Ignition Process 1) Unlock system 2) Set desired parameters 3) Press the ON button 4) Pre-Purge - 120 second countdown displayed– Red LED ON 5) Audible Alarm - 5 second countdown - Green LED ON 6) Igniter on - 5 second countdown- Green and Amber LED ON 7) Stage 1 Solenoid valve opens - igniter remains on - Green, Blue and Amber LED ON 8) Ignition is achieved, flame is sensed - Green and Blue LED ON 9) Stage 2 solenoid valve opens - once the timing between solenoids expires - Green and Blue LED ON...
  • Page 35 STANDING PILOT OPERATION Flow Chart...
  • Page 36 PILOTLESS OPERATION Ignition Process 1) Unlock system 2) Set desired parameters 3) Press the ON button 4) Pre-Purge - 120 second countdown displayed– Red LED ON 5) Audible Alarm - 5 second countdown - Green LED ON 6) Igniter on - 5 second countdown- 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 9) System is running - Status code 00 - Green and Blue LED ON...
  • Page 37 PILOTLESS OPERATION Flow Chart...

  • Page 38: Specifications

    SPECIFICATIONS Power Supply Specifications Device Specification Battery Volts 11-15 VDC 12 VDC Power Supply SET @ 13.4 VDC, 10 Amps Solar Panel 12 VDC Type Solar Panel Max System Amperage 7.8 Amps / 0.6 Amps Avg. Ignition Unit Specifications Device Specification Igniter Current Draw 7.5 Amps Inrush, 2.0 Amps NOM (during normal operation)

  • Page 39: Basic Troubleshooting

    TROUBLESHOOTING GUIDE RUN CODES Code Symptom Action Visual Pilot/main burner is Normal operation. Blue and Green   Successful ignition recorded LEDs ON  System Process is increasing to temperature.  Running Pilot/main burner is Normal operation. Red LED ON  ...
  • Page 40 TROUBLESHOOTING GUIDE STANDBY CODES Code Symptom Action Visual Pilot/main burner is not No jumper at ports 23 and Blinking Green LED   Spare Standby 1 Igniter is not lighting Customer supplied switch is   gas. activated. No activity when system Check wire connections.
  • Page 41 TROUBLESHOOTING GUIDE SHUTDOWN CODES Code Symptom Action Visual Pilot/main burner Check fuel supply. Blinking Red   is not on. Check power supply.  Max Retries Ignition failed Check air/fuel mixer.   Exceeded three consecutive Ensure burner pressures are within ap- ...
  • Page 42 TROUBLESHOOTING GUIDE SHUTDOWN CODES Code Symptom Action Visual Pilot/main burner Ensure igniter wires are terminated Blinking Amber and   is not on. properly. Red LEDs Igniter Open Circuit System will pro- Check for disconnected wires   ceed through Igniter element could have wore out ...
  • Page 43 TROUBLESHOOTING GUIDE SHUTDOWN CODES Code Symptom Action Visual Pilot/main burner No jumper at ports 19 and 20. Blinking Red LED   is not on. Customer supplied device is activated.  ESD Activated No activity when Check wire connections.   system is attempt- ing startup.
  • Page 44 The Modbus registers, their contents, command sequencing and examples of command execution over Modbus are described. This document applies to Modbus firmware version 1.8. In order to use Modbus with the BMS-300, the BMS-300 firmware needs to be version 3.5.

  • Page 45: Modbus Information

    Address 40001 maps to Register 1 Address 40002 maps to Register 2   Address 40256 maps to Register 256 The following table is the register map for the BMS-300. Bits are in MSB first order. Modbus Register name Data type Notes...
  • Page 46 MODBUS INFORAMTION Modbus Register name Data type Notes address Modbus master does R (Read) 40005 Configuration and status unsigned int 16 Bit 0 – Light status 0 : RED light is on solid 1 : GREEN light is on solid Bit 1 – Temperature units 0 : Degrees C 1 : Degrees F Bit 2 –...
  • Page 47 MODBUS INFORMATION Modbus Register name Data type Notes address Modbus master does R (Read) 40010 Command status(R) unsigned int 16 0x55 IDLE - Ready for new command 0x01 Command executed OK 0x02 Bad command, nothing done 0x03 BMS read of exec reg from Mod- board timed out 0x04 BMS read of exec packet from Mod- board had bad checksum...
  • Page 48 MODBUS INFORAMTION Modbus Register name Data type Notes address Modbus master does R (Read) 40023 Bit 3 - Igniter volts unsigned int 16 Bit #3 of register 40005 unpacked into a single 0 : 14V register for use by controllers with primitive bit 1 : 13V manipulation capabilities.
  • Page 49 MODBUS INFORMATION Modbus Register name Data type Notes address Modbus master does R (Read) 40032 Bit 12 – Standby inter- unsigned int 16 Bit #12 of register 40005 unpacked into a single lock register for use by controllers with primitive bit 0 : Clear manipulation capabilities.
  • Page 50 MODBUS INFORAMTION 4.0 DIP switch configuration and settings Switch SW1 on the Modbus board configures the Modbus address, baud rate, and selects the serial interface to be used. The notation “ON” and “OFF” follows from the direction of the arrow and the word “ON” located on the left side of the switch body near SW1-1.
  • Page 51 MODBUS INFORMATION Desired Mod- SW1-1 SW1-2 SW1-3 SW1-4 SW1-5...
  • Page 52 POSSIBLE SOLUTIONS: 1. Limit the number of registers being read from the BMS-300 during each transfer to about 10 or less. 2. Limit the polling interval to about twice per second.

  • Page 53: Bms-300 Software Versions

    SOFTWARE VERSIONS BMS-300 Software Version Release Date Description V 3.5 4/2/2019 Standard base software MODBUS Software Version Release Date Description Standard base software V 1.8 5/6/2013 (Read only) Serial Number: Software Version:...

  • Page 54: Contact Information & Manual Version

    BMS-300 Installation and Operations Manual 11/23/2015 Last Update: 05/8/2019 Version 7.0 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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