Surefire BMS-350 User manual

Proudly Made in
the USA
BMS-350
Installation and
Operations Manual

2
BMS-350
The BMS-350 is designed for heavy-duty oil field applications, and possesses Class 1 Division 2 certification
standards. The BMS-350 is designed to operate utilizing the SureFire FT ignition series to operate and monitor
process equipment, flare, and combustor application .
The controller’s display is designed to operate in ambient temperatures from – 40° F to 131° F, and is coated
for corrosion resistance. The unit is mounted in a NEMA 4X enclosure and supplied with a UV resistant key-
pad. Each unit includes function indicator LEDs, and a status code chart to provide assistance in troubleshoot-
ing situations. The unit requires 12V DC power, and is solar ready with a specific solar power termination
port.
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. The system’s fail safe run
status / alarm out functions allow for remote monitoring for environmental and regulatory compliance. Stand-
ard remote feature include temperature indication utilizing an RTU or PLC, and Modbus read/write communi-
cation through both RS-485 or RS-232.
The BMS-300 process may also be controlled using the alt sense input. Multiple connections for additional
standby and shutdown requirements are also provided.
Every SureFire system must pass complete factory QA/QC inspections before shipment.
Also available are control solenoid valves, resistance temperature detector (RTD), Thermocouple (T/C), flame
sensor, fuel loss standby switch and FT ignition series.
We are dedicated to providing quality American made safety control systems for industrial burners. The BMS
system has been developed through thousands of hours of critical design, engineering, and field testing.
INTRODUCTION


3
Certifications and Warnings 4
Warranty Statement 5
BMS-350 Description
Enclosure 6
Circuit Board 7
LED Indicators 8
Graphic Overlay 8
Keypad Functions 9
Component Descriptions
SureFire Ignition Units 10-11
Additional Components 12-13
Installation Guide 14-17
Installation Wiring Diagram 18
Fuel Train Diagrams 19
Controller Setup 20-25
Operation Guide 26-27
Operation / Flow Chart: Piloted and Pilotless System 28-33
Specifications 34
Troubleshooting Guide 35-40
Modbus Information 41-54
Software Versions 55
Contact Information and Manual Version 56
TABLEOFCONTENTS


4
CERTIFICATIONSANDWARNINGS

WARNING -
EXPLOSION HAZARD – SUBSTITUTION OF COMPONENTS MAY IMPAIR
SUITABILITY FOR CLASS I, DIVISION 2;
AVERTISSEMENT -
RISQUE D'EXPLOSION – LA SUBSTITUTION DE COMPOSANTS PEUT RENDRE CE MATERIEL
INACCEPTABLE POUR LES EMPLACEMENTS DE CLASSE I, DIVISION 2
WARNING -
EXPLOSION HAZARD - DO NOT REPLACE FUSES UNLESS POWER HAS BEEN SWITCHED OFF
OR THE AREA IS KNOWN TO BE NON-HAZARDOUS;
AVERTISSEMENT -
RISQUE D'EXPLOSION - COUPER LE COURANT OU S'ASSURER QUE L'EMPLACEMENT EST
DESIGNE NON DANGEREUX AVANT DE REPLACER LE FUSE.
WARNING -
EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN
SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS;
AVERTISSEMENT -
RISQUE D'EXPLOSION - AVANT DE DECONNECTER L'EQUIPEMENT, COUPER LE COURANT OU
S'ASSURER QUE L'EMPLACEMENT EST DESIGNE NON DANGEREUX.
WARNING -
EXPOSURE TO SOME CHEMICALS MAY DEGRADE THE SEALING
PROPERTIES OF MATERIALS USED IN THE FOLLOWING DEVICES: PANASONIC RELAY, MODEL JW2SN-DC12V, AND HAMILIN RE-
LAY, MODEL HE721A0500
AVERTISSEMENT -
L'exposition à certains produits chimiques peut dégrader les ETANCHEITE
Propriétés des matériaux utilisés dans les dispositifs suivants: RELAIS PANASONIC MODÈLE JW2SN-DC12V, ET RELAIS HAMILIN,
MODÈLE HE721A0500
7.8 amps @ 12.0 VDC MAX
0.025 amps @ 12.0 VDC AVG
ETL Certified to the Following
Standards:
Certified To:
CSA STD C22.2 No. 61010 -1
CSA STD C22.2 #213
Conforms To:
UL STD 61010 –1
ISA STD 12.12.01

5
WARRANTYSTATEMENT

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.
Farmington, NM, USA of such defective equipment. SureFire’s obligation under this warranty is
limited to the above and does not apply to claims which are a result of improper installation, mis-
use, maladjustment, abnormal operating conditions, or lack of routine maintenance as determined
by SureFire. Nor does the warranty include the furnishing of service for maintenance or problems
arising from the foregoing causes. No claims for labor, installation, removal, transportation, or oth-
er expenses will be recognized. Notwithstanding any stipulation of the purchaser to the contrary, all
other obligations, representations, warranties and conditions, express or implied, statutory or other-
wise, including any implied warranties or conditions of merchantability, quality or fitness are here-
by excluded and, 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. The provisions hereof relating to the warranty and limitations hereon and limitation of lia-
bility shall continue to be enforceable between the parties notwithstanding termination of the with-
in agreement for any reason including fundamental breach. Equipment not of SureFire manufacture
shall pass through to the end user the vendor’s or manufacturer’s standard warranty.

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:
 Windblown Dust Protection
 Water Damage Protection - Rain, Sleet, Snow, Splashing and Direct Water Contact
 Corrosion Protection
 External Formation of Ice Protection
The Enclosure is IP66 certified, meaning it has been tested to the following:
 Dust tight, no ingress of dust; complete protection against contact
 Water projected in powerful water jets (12.5mm nozzle) against the enclosure from any direction
shall have no harmful effects.
WARNING:
When drilling holes in the enclosure, ensure IP66 fittings are used to maintain the IP66 standard. Failure to
use IP66 standard fittings nullifies the IP66 certification.

7
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-
dividual spring loaded terminal blocks for ease of wiring termination and installation.

8
BMS‐350DESCRIPTION

Graphic Overlay
The overlay has commonly used status codes printed on the face. The overlay is used for interfacing with
the program and setting up the unit.
LED Indicator Status
LED ON - Indicates that the system is on and operating properly
Blinking - Indicates a standby interlock is activated
RED LED ON - Indicates that the system is off
Blinking - Indicates a shutdown failure or interlock has been activated
AMBER LED ON - Indicates the igniter is on
Blinking - Indicates an igniter failure
BLUE LED ON - Indicates that a flame has been sensed
GREEN
LED Indicators
The circuit board LEDs illuminate through the lid of the enclosure. The LEDs indicate the following:

9
BMS‐350DESCRIPTION

Keypad Functions
The SureFire BMS-350 has a 16 button keypad to assist in controlling and monitoring the system.
Button Functions
Up Arrow Increases the current value
Press & hold for 5 seconds to unlock the system - A series of zeros will appear on the display screen
Down Arrow Decreases the current value
Press & hold for 5 seconds to re-lock system.
High Temp Displays High Temperature setting
Locked Mode - Press & hold for 5 seconds to display the Safety Thermocouple’s current temperature
Low Temp Displays Low Temperature setting
Flame Sense Displays current flame sensing device
F - Flame Rod H - Thermocouple
Temp Control Displays current controlling device
A - Alt Sense 1 - RTD 2 - Thermocouple
Status Code Displays code that corresponds with the current unit status
Press & hold, use the up & down arrows to display the past 9 codes
EHTD Displays current Extreme High Temp Delta setting
Battery Volts
Pilot Mode 1/2 Displays current pilot mode
1 - Intermittent Pilot 2 - Standing Pilot
FPT Displays current Flame Proof Timing setting
Solenoid Timing Displays current timing between stage 1 & stage 2 opening
Flame Strength Displays current flame strength for the Flame Rod or Thermocouple
Press & hold for 5 seconds to display the Safety Thermocouple shutdown setting
AUX
Displays current igniter Ohms
Press & hold, use the up & down arrow button to display: System days On, Burner Days On, Ignition
Attempts & Successful Ignitions.
OFF Turns system OFF
ON Turns system ON
Displays current voltage being supplied to the unit.
Primary
Secondary
Primary
Secondary
Primary
Secondary
Primary
Secondary
Primary
Secondary
Primary
Secondary

10
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.
NOTE: Please consult local SureFire Field Tech Support
for proper pilot placement and proper orifice sizing selec-
tion.
FT-1-SF (above)
These unit above is utilizing a Flame Rod as
a flame sensing mechanism.
Optional Flame Sensors
Flame Rod
 Nichrome flame rod rated to 2600°F
 Armored wiring harness rated to 1000°F duty / 1500°F
flash
 Enclosed fire tube service
 Direct termination to BMS-350 controller
Thermocouple
 Type K thermocouple flame sensing rated to 2400°F
 Armored wiring harness rated to 1000°F duty / 1500°F
flash
 Exposed combustor or incinerator service
 Direct termination to the BMS-350 controller
FT-1-ST (above)
These unit above is utilizing a Thermocouple
as a flame sensing mechanism.

11
COMPONENTDESCRIPTION

Pilotless Systems
The pilotless systems offer ease of installation for a
range of applications. Each of these units are available
with flame rod or thermocouple flame sensing.
 FT-2 Systems are suitable for pilotless 1” burner
applications, rated at 125,000 btu/H
 FT-4 Systems are suitable for pilotless 2” burner
applications, rated at 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-2-AF:
This unit above is utilizing a Flame Rod
as a flame sensing mechanism.
FT-4-AF (above) and FT-6-AF (below):
These two unit are utilizing a
Flame Rod as a flame sensing mechanism.

12
COMPONENTDESCRIPTIONS

1in. & 2in. SureFire Solenoid Valve
 The 1in. SureFire solenoid valve is a fail closed device,
meaning if power is lost, the unit defaults to a closed state
 No adjustment necessary! Simple 2 wire termination
 Kalrez elastomer plunger.
 Plunger replacement kits available.
 Applications include - pilotless operation, non-venting fuel
trains, and flares
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
 Simple 3 wire termination
 Proof of valve closure kits available
 Applications include - pilotless operations , non-venting
fuel trains, and flare systems
1/4 in. ASCO Solenoid Valve
 The 1/4 in ASCO solenoid valve is a fail closed device,
meaning if power is lost, the unit defaults to a closed state.
 No adjustment necessary! Simple 2 wire termination.
 1/4” NPT X 1/4” NPT connection
 Applications include– direct pilot control valve (#70 ori-
fice) and pneumatic valve operation.
Please Contact SureFire for appropriate product part number.

13
COMPONENTDESCRIPTIONS

Pressure Switch
 Used on a variety of standbys and shutdowns
 Can be set as normally open or normally closed.
 Adjustable from 1 psi — 15 psi.
 316 SS construction, wetted parts are NACE
Resistance Temperature Detector
 Used to detect the process temperature.
 Temperature range is 0°F — 670°F.
 Simple three wire termination.
 1/2” NPT X 1/2” NPT connection
 Available in the following sizes: 5”, 6”, 9”, 12”, and 18”.
Slow Flow Valve
 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.
 1/4” NPT X 1/4” NPT connection
 Recommended for piloted installations to assure optimum
performance and reliability.
Thermocouple
 Type K thermocouple used to detect the process tempera-
ture.
 Temperature range is 32°F — 2400°F.
 Simple two wire termination.
 1/2” NPTX 1/2” NPT connection
 Available in the following sizes: 6” and 9”.
Please Contact SureFire for appropriate product part number.
Please Contact SureFire for appropriate product part number.

14
INSTALLATIONGUIDE
Enclosure Installation
1. The enclosure is to be mounted on a pole or a building that
is capable of supporting a minimum of 10 lbs.
2. Position the enclosure so that the LED display is clearly
visible for the operator
3. Install conduit seal-off fittings for ALL electrical
connections at the box
4. Installation must comply with the local electric code.
WARNING: Before any welding is attempted, disconnect all wires going to the circuit
board.
PLC/ Scada Connection
1. Make the connections from the RTU/PLC to the
Run Status terminals (Port 4-5)
2. Make the connections from the RTU/PLC to the
Alarm output terminal (Ports 6-7)
NOTE: These terminals are left un-touched if not
used.
NOTE: Please see operation table on page 27.
MounngHardware
UnistrutClamp
Unistrut
Actuator Valve Installation
1. Install the SureFire approved Actuator Valve
2. Terminate the Actuator wires (1, 2 and 3) at the Actuator
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.
WARNING: Before terminating any wires, be sure no power is supplied to the controller.
NOTE: After completing your installation and confirming proper operation, lock or tag your control unit box
to prevent unwanted or unauthorized modifications.

15
INSTALLATIONGUIDE

RTD
1. Install the RTD into the provided thermo-well on the
vessel.
2. Connect the two negative wires to the negative termi-
nals (Ports10-11) on the circuit board.
3. Connect the one positive wire to the positive terminal
(Port 12).
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.
2. Connect positive side of the power supply from the remote monitoring
equipment to positive port and the negative wire to the negative port of the
4-20mA terminal.
3. If a 1-5 V signal is desired instead of the 4-20m, please install a 250 Ω resistor (at the remote moni-
toring equipment) to the return in step 2 and connect the other end of the resistor to the NEG side
of the power supply. Monitor the VDC signal at the 250 Ω resistor (return wire).
RTD Scaling: 4 mA = 0 °F
20 mA= 670 °F
T/C Scaling: 4 mA = 32 °F
20 mA = 2400 °F
PLC/ Scada Connection (Cont.)
Solenoid Valve
1. Ensure instrument gas is shut off.
2. Locate the instrument gas supply line feeding the main burner
valve.
3. Cut the supply tubing, allowing enough room for the solenoid
to be installed in close proximity to the SureFire Controller.
4. Use two 1/4” NPT x 3/8” tubing fittings and connect the
solenoid in-line.
5. Trim the unused GREEN wire short and cap it off with a wire
nut as this will not be used.
6. Use the proper conduit and connectors and wire the solenoid to the
SureFire system.
Stage 1 Solenoid terminated to ports 8 and 9.
Stage 2 Solenoid terminated to ports 18 and 19.
Note: Reference solenoid body for proper
flow direction. 1 = Outlet 2 = Inlet

16
INSTALLATIONGUIDE

Shutdown/Standby Installation
1. Install a switching device in one of the assigned terminals
(Ports 20-21, 22-23 & 24-25)
2. If a switching device is not installed, place a jumper in the
assigned terminals.
NOTE: Closed Contact = Clear
Open Contact = Activated
Solar Panel Installation
1. Install a 12 VDC solar panel and mount facing southeast.
2. Make the connection from the negative side of the solar
panel to the negative terminal (Port 32)
3. Make connect from the positive side of the solar panel to
the positive terminal (Port 33)
NOTE: Internal regulator to trickle charge 12VDC battery.
NOTE: 75 Watt solar panel is
the max allowable solar panel
size
Proof of Valve Closure
1. Install a main burner valve with a switch to provide proof
of closure and terminate at ports 26 & 27.
2. If not used, place a jumper in the assigned terminal. NOTE: Do Not use as a Shutdown
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. If using a thermocouple for a high temperature
shutdown, make the connection from the positive lead
of the thermocouple (yellow) to the positive terminal
(Port 15) and the negative lead of the thermocouple
(red) to the negative terminal (Port 16).
NOTE: If not using the Thermocouple high temp shut-
down, place jumper in termination port 15 & 16.

17
INSTALLATIONGUIDE

NOTE:
If utilizing 12 VDC power
supply, set voltage @ 13.4 VDC.
Power supply should be rated for
90 + watts
SureFire Ignition Unit
1. Ensure all supply gas is turned off and locked out/ tagged
out.
2. Install the FT unit in the fire tube.
3. The igniter has two wires that are white in color. These
wires are not polar sensitive. Terminate wires to ports 30
and 31.
4. Verify continuity for all wiring prior to reinstalling burner
into the fire tube.
Flame Sensing
Flame sensing mechanism will be dependent on the ignition unit
being utilized.
 For flame rod flame sensing terminate flame rod wire at des-
ignated port on upper left hand corner of the circuit board.
 Isolated grounding is required. Terminate ground wire to cir-
cuit board labeled Chassis Ground and ground screw on GUA
on arrestor housing.
NOTE: Please do not bond the flame sensing ground to facility ground to
avoid flame sensing disruption.
 For thermocouple flame sensing terminate the red (-) wire and
yellow (+) to the designated ports in the upper left corner of
the circuit board.
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)
3. Make the connection from the positive side of the battery to the
positive terminal (Port 35)
4. Install a circuit breaker/disconnect switch rated @ 10 amps, inline
between the battery and the circuit board for an accessible discon-
nect of power.

18
INSTALLATIONWIRINGDIAGRAM

19
FUELTRAINDIAGRAMS

Piloted Fuel Train
Pilotless Fuel Train

20
CONTROLLERSETUP

High Temperature
Primary Function:
 The High Temp button displays the current high temperature setting.
 To set or change the High Temperature, follow these steps:
1. Press the high temp button to view current high temperature setting.
2. Unlock the system by pressing and holding the up arrow button for 5 seconds until a series of zeros
appears.
3. Press and hold the high temp button and use the up or down arrow buttons to adjust the tempera-
ture setting. (Press and hold the up or down arrows for 5 seconds to scroll).
NOTE: High temp factory setting: RTD = 120°F / TC = 1800°F
High temp range: RTD = 34°F — 590°F / TC = 34°F — 2400°F
Secondary Function:
 The High Temp button displays the safety thermocouple’s current temperature when pressed and held for
5 seconds in the locked mode.
Low Temperature
 The Low Temp button displays the current low temperature setting.
 To set or change the Low Temperature, follow these steps:
1. Press the low temp button to view current low temperature setting.
2. Unlock the system by pressing and holding the up arrow for 5 seconds until a series of zeros
appear.
3. Press and hold the low temp button and use the up or down arrow buttons to adjust the temperature
setting. (Press and hold the up or down arrows for 5 seconds to scroll.)
NOTE: Low temp factory setting: RTD = 100°F / 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.