Canalta Combustex BMS-2000 User manual

The Combustex BMS-2000
OPERATIONS MANUAL
OPERATION CONFIGURATION CALIBRATION INSTALLATION
B149.3 Compliant Burner Mangagement System
BMS Software Version 5.03

Phone: [phone] |Web: www.combustex.com
For operational, technical or installation assistance, please contact us.
QUALITY, RELIABILITY, PERFORMANCE
With Control Comes Safety
The BMS-2000 Burner Management System gives you the automated control to safely start,
monitor and manage a single or dual burner gas-red industrial heater.
• Calibrate, tune and congure more than 60 parameters and variables via the front keypad.
• Maintain system security through password protection.
• Access a wide selection of sequencing, monitoring and control information through easy page scrolling
on the heated, back-lit display.
• Gain exibility with remote and local start / shutdown / set point capabilities.
• Take control of shutdowns with rst out annunciation and a direct readout of shutdown conditions.
With the BMS-2000, You Have Exceptional Control
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ANSI Z21.20 - 2007
CSA C22.2 No. 199 - B149.3 Compliant
CSA 22.2 No. 213 - M1987
UL 1998
UL 372
Class 1, Div. 2 Groups B, C and D Haz. Loc.
Temp. Code T4
NEMA Type 4x
Standards & Certications
4003497

The Combustex BMS-2000
Burner Management System
OPERATIONS MANUAL
Controller Version 5.03
Phone: [phone] |Web: www.canaltaow.com
For operational, technical or installation assistance, please contact us.
WARNINGS
Combustex recommends that this manual be read thoroughly before
attempting installation or operation of the BMS-2000. SAFETY FIRST.
Call Us Toll Free: 1-855-226-2582
-- WARNING --
THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS 1, DIVISION 2 GROUPS B, C, D OR
NON-HAZARDOUS LOCATIONS ONLY.
-- WARNING --
EXPLOSION HAZARD - DO NOT DISCONECT EQUIPMENT WHILE CIRCUIT IS LIVE
UNLESS AREA IS KNOWN TO BE NON-HAZARDOUS
-- WARNING --
EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY
FOR CLASS 1, DIVISION 2 LOCATIONS.
-- AVERTISSEMENT --
RISQUE D’EXPLOSION - LA SUBSTITUTION DE COMPOSANTS PEUT RENDRE CE
MATERIEL INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE 1, DIVISION 2.
-- ADVERTENCIA --
PELIGRO DE EXPLOSION - LA SUSTITUCION DE LOS COMPONENTES PUEDE
AFECTAR LA COMPATIBILIDAD PARA CLASE 1, LOCALIZACION DE DIVISION 2

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Combustex BMS-2000 [5.03] Operations Manual
Phone: [phone] |Web: www.canaltaow.com
For operational, technical or installation assistance, please contact us.
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CONTENTS
1. INTRODUCTION
1.1 Overview
1.2 Burner Sequencing
1.3 ESD (Emergency Shutdown) Capabilities
1.4 Temperature Control
1.5 Features
1.6 Communications
1.7 Denitions of Common Terms and Abbreviations
1.8 Technical Specications
2. OPERATION
2.1 Overview
2.2 Passwords - Gaining Entry
2.3 Sequence Status & Shutdown Annunciation
2.4 Temperature Control
2.5 Output Status
2.6 Auxiliary Analog Inputs and Shutdowns
2.7 PID & Control Parameters
3. CONFIGURATION OF THE BMS-2000
3.1 Overview
3.2 Conguration Menu Options
4. CALIBRATION OF THE BMS-2000
4.1 Overview
4.2 Calibration Menu Items
4.3 Thermocouple / mV Reference Chart
5. INSTALLATION
5.1 Overview
5.2 Analog Input Connections
5.3 Digital Input Connections
5.4 Analog Output Connections
5.5 Digital Output Connections
5.6 Modbus Connections
5.7 Sample P&ID Drawings & Wiring Diagrams
6. TROUBLESHOOTING SHUTDOWN CONDITIONS
6.1 Error Messages and Shutdown Conditions
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Combustex BMS-2000 [5.03] Operations Manual - 1. INTRODUCTION
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INTRODUCTION
1.1 OVERVIEW
The Combustex BMS-2000 Burner Management System has been designed to be compatible with a wide
variety of industrial and oileld burner vessels. A common vessel will have a main burner ring into a re
tube which, in turn, heats a uid (often glycol). This uid is referred to as the “Bath”. Another uid (oil or
gas) is routed through the bath to be heated. This is referred to as the“Process”.
The BMS will control up to two pilots and two main burners, handle temperature control of the bath, and
provide ame status outputs and a variety of ESD (emergency shutdown) inputs.
The BMS-2000 is typically installed together with a Pilot Pro™ Series Ignition Assembly. These igniters
are designed and built around the features of the BMS, allowing the BMS to light and maintain a pilot
ame using the sensor that is incorporated into the pilot ignition module, providing ame verication.
The Combustex BMS-2000 is suitable for both new installations and retrotting older vessels, and is not
limited to Pilot Pro™ igniters.

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Combustex BMS-2000 [5.03] Operations Manual - 1. INTRODUCTION
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For operational, technical or installation assistance, please contact us.
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1.3 EMERGENCY SHUTDOWN CAPABILITIES
The BMS-2000 can be congured to shut down when an unsafe or out-of-control condition exists.
1. Programmable HTSD limits on:
• Bath Thermocouple Input
• Process Thermocouple Input
• Stack Thermocouple Input
2. Standard dedicated discrete eld device inputs preset at the factory:
• Remote Stop
• Remote Start
• Low Voltage
• Burner #1 Flame Sensor Failure
• Burner #1 Flame Failure to Relight
• Burner #1 Fuel Gas Low Pressure
• Burner #1 Fuel Gas High Pressure
• Aux. High Bath Temp. (Contact)
• Low Bath Level
• Burner #1 Main Valve Proof of Closure
3. Additional inputs for Dual Burner Systems:
• Burner #2 Flame Sensor Failure
• Burner #2 Flame Failure to Relight
• Burner #2 Fuel Gas Low Pressure
• Burner #2 Fuel Gas High Pressure
• Burner #2 Main Valve Proof of Closure
1.2 BURNER SEQUENCING
When initiating a start sequence, the BMS will open the pilot and energize the igniter for the trial for
ignition period and wait for the ame sensor to conrm a ame. Upon ame verication, the unit will
then go into “Normal Operation”. At this point, the BMS will energize the main burner and the ame
status output(s). The temperature control option will also become enabled (if congured).
Set points and the associated password protected timers are congurable in the BMS menu. Other
congurable options:
• Purge and Pre-purge
• Auto Relight on Flame Fail
• Auto Relight on Power Fail (unit will relight when power is restored)

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Combustex BMS-2000 [5.03] Operations Manual - 1. INTRODUCTION
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1.5 FEATURES
Automatic Sequencing Features
• LCD backlight, which can be set to ON, OFF, AUTO (with photocell) or TIMED.
• LCD heater, which automatically turns on at -10°C (14°F) to maintain display stability.
• Available computer interface via RS232 or RS485 Modbus protocol.
• Input ltering to help alleviate noisy signals and signal spikes.
• Capable of driving latching solenoids (separate latch and unlatch outputs).
• Single or dual burner control (selectable in series or parallel).
• Auto relight sequence can be de-selected or selected with up to three relight attempts after loss of
ame.
• Congurable pre- and post-purge times and auxiliary blower with conrmation.
• Congurable ame sensor options.
• Ignition output signal can be congured as steady or pulsed.
• Wide variety of congurable safety interlock devices (factory set to standard settings).
• Remote start / stop is congurable.
• Auto startup after power failure is congurable.
• Intermittent pilot or standing pilot is congurable.
• Remote indication of temperatures via 4-20 mA output.
• Remote set point of bath available via 4-20 mA input.
• Conguration is password protected and stored in non-volatile memory.
Shutdown Annunciation Features
• A rst out annunciation is built in with direct readout of the shutdown conditions. Each shutdown
condition is marked with its chronological incoming position. The operator must acknowledge
each shutdown condition and the condition must be cleared before startup can be initiated.
1.4 TEMPERATURE CONTROL
The BMS-2000 can be congured to perform bath temperature control by a Proportional or ON/OFF
Control output.
Proportional Control:
One 4-20mA output will be used. Set point and PID parameters are congurable via the BMS-2000
keypad.
ON/OFF Control:
The main #1 (and main #2, if applicable) burner will be cycled on and o to maintain set point. The
ON/OFF dead band and set point is adjustable via the BMS-2000 keypad.

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Combustex BMS-2000 [5.03] Operations Manual - 1. INTRODUCTION
Phone: [phone] |Web: www.canaltaow.com
For operational, technical or installation assistance, please contact us.
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1.8 TECHNICAL SPECIFICATIONS
Rating CSA Class 1, Div. 2; Class 1, Div. 1 (pending); Intrinsically Safe; Nema 4x; B149.3 Compliant
Enclosure Dimensions 10.5” H, 8.5”W, 6” D
Enclosure Construction Molded Fiberglass Polyester with Quick Release Latches
Operating Temperature - 40°C to + 40°C (-40°F to +104°F)
Inputs (12) Digital Solid State; (2) Analog 4-20mA;
(5) Thermocouple Type K Underground Cold Junction Compensated
Outputs (16) 12-30 VDC Digital Solid State Optical Isolated (1.5A each)
(2) Analog 4-20mA 500 Ohm (max.)
Power Supply 12 to 30 VDC Clean Filtered
Current Draw
80 mA (min), 160 mA (typical), 300 mA (max) for Electronics + LCD Backlight + Display
Heater. Current draw of solenoids and other devices driven by BMS will have to be
added to above to calculate total. Total current draw not to exceed 3A.
Display Low Temp. Heated LCD
Mounting Wall Mount Bracket Standard; 2”Pipe Mount Optional
Communication Digital, Analog and Modbus
1.7 DEFINITIONS AND ABBREVIATIONS
Dead Band The allowed deviation from set point (while in ON/OFF Control)
DI Discrete Input
ESD Emergency Shutdown
HTSD High Temperature Shutdown
LCD Liquid Crystal Display
PID Proportional, Integral (Reset), Derivative (Rate)
PV Process Variable (Actual Temperature)
SD or S/D Shutdown
SP Set Point (Desired Temperature)
1.6 COMMUNICATIONS
The Combustex BMS-2000 includes both analog (9 total) and digital (28 total) connections for
communication between the BMS controller and various combustion system monitoring and control
devices. In addition, the BMS oers Modbus connectivity for fast, robust communication between the
BMS unit and remote controllers and readout devices. Modbus protocols RS232 and RS485 can be used
to remotely monitor and congure a select list of settings and status readouts. This functionality is
available in both single and dual-burner versions of the Combustex BMS-2000.

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Combustex BMS-2000 [5.03] Operations Manual - 2. OPERATION
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For operational, technical or installation assistance, please contact us.
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Start Key
Stop Key
LCD Display
Configuration Key
Calibration Key
Auto Backlight Sensor
Acknowledge Key
Page Scroll Key
Up Key
Down Key
Select Item Key
2.1 OVERVIEW
The operator interface of the BMS-2000 consists of two components:
• Heated, Back-lit LCD Alphanumeric Display
• 9-Key Membrane Keypad
OPERATION
Keypad functions:
• START initiates the automatic ignition sequence of the pilot and BMS. Once the pilot ame is
proven, the BMS will continue into NORMAL OPERATION.
Note: the BMS display must read “CLEAR TO START” in order to initiate startup sequence.
• STOP cancels the ignition sequence and / or shutdown the operation of the BMS and pilot
by closing all fuel train valves and extinguishing the pilot ame. A shutdown reading
of “LOCAL MANUAL S/D” will be displayed on BMS display page 1, indicating the STOP
button has been pressed.
• ACK clears any active shutdowns displayed on BMS display page 1. This key also acknowledges
passwords and selects items in the calibration and conguration menus for adjustment.
Note: active shutdowns will only be cleared from the display if they have been cleared in the
eld and a safe condition exists. If the ACK button is pressed and a shutdown has not
been eld-cleared, a *symbol will appear beside the shutdown, indicating that it has
been acknowledged by the operator, but the error still exists in the eld.

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Combustex BMS-2000 [5.03] Operations Manual - 2. OPERATION
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Upon power-up, the introduction message and controller version will be displayed:
From the main display, the user can scroll through ve dierent pages.
To enable the scroll function:
1. Press the ‘PAGE SCROLL’ button. Notice that the >symbol appears beside the page number in the
top left-hand corner of the display.
2. Press the  and  buttons to go to the desired page.
Burner Management System V 5.03
REV 2.xx
1>
Low Input Voltage 1 of 3
• CONFIG allows the user access to the Conguration Menu.
Note: BMS must be shut down (not in NORMAL OPERATION) in order to access the
Conguration Menu.
Note: Conguration Menu is password protected.
• CALIB allows the user access to the Calibration Menu.
Note: BMS must be shut down (not in NORMAL OPERATION) in order to access the
Calibration Menu.
Note: Calibration Menu is password protected.
• PAGE SCROLL / EXIT displays a >symbol beside the page number in the top left corner of the
BMS display, indicating that the user may scroll through the pages by pressing the arrow keys.
PAGE SCROLL is also used to exit the Conguration and Calibration Menus.
• SELECT ITEM allows the user to scroll through any active shutdowns on BMS display page 1,
change the control parameters on page 2, and adjust settings on pages 4 and 5 (using the
arrow keys). SELECT ITEM also moves the cursor from right to left when inputting any
password or numerical value.
• The arrows are used to scroll through pages, scroll through the Conguration and
Calibration Menus, and adjust settings and numerical values.