Surefire BMS-300 User manual

Proudly Made in
the USA
BMS-300
Installation and
Operations Manual

2
BMS-300
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. The unit is mounted in a NEMA 4X enclosure supplied with a UV resistant keypad. Each
unit includes function indicator lights, and a status code chart printed on the overlay to provide assistance in
troubleshooting. The units require 12 VDC or 24 VDC power, and is solar ready with a specific solar power
termination port.
The system monitors target temperature with an enhanced RTD circuit; and indicates temperatures from 0°F to
500°F. The system controls both the pilot and main burner gas valves as necessary, and is designed as a fail
safe system. High temperature and flame failure shutdowns are available, along with an audible startup
warning. The system’s failsafe run status alarm function allows for remote monitoring for environmental and
regulatory compliance. Standard remote features include temperature indication, remote ON and OFF utilizing
RTU and PLC.
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. Also available are: control solenoids valves,
resistance temperature detector (RTD), flame sensor, loss of fuel or standby pressure switches, and an FT-
series ignition unit
We are dedicated to providing quality American-made safety control systems for industrial burners. The
system has been developed through thousands of hours of critical design, engineering, and field testing.
INTRODUCTION


3
TABLEOFCONTENTS

Certifications and Warnings 4
Warranty Statement 5
BMS-300 Description
Enclosure 6
Circuit Board 7
LED Indicators 8
Graphic Overlay 8
Keypad Functions 9
Component Description
SureFireIgnitionUnits 10-11
Additional Components 12-13
InstallationGuide 14-19
Installation Wiring Diagram 20
Fuel Train Diagram 21
ControllerSetup 22-29
Operation Guide 30-31
Operation / Flow Chart: Piloted and Pilotless System 32-37
Specifications 38
Basic Troubleshooting 39-43
InstallationNotes 44
BMS-300 Software Versions 45
Contact Information & Manual Version 46

4
CERTIFICATIONSANDWARNINGS

Suitable for use in Class I, Division 2,
Groups C, D, T6 Hazardous
(Classified) and Ordinary Location
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 EMPLACE-
MENTS 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 DEVIC-
ES: Panasonic Relay, Model JW2SN-DC12V, and Hamlin Relay, Model HE721A0500
AVERTISSEMENT -
L'exposition à certains produits chimiques peuvent dégrader les FERMETURE PROPRIETES des matériaux utilisés dans les appareils suivants: Panason-
ic Relais, modèle JW2SN-DC12V, et Hamlin Relais, modèleHE721A0500
Operation - 40°C ( - 40°F ) ≤
Amb. Temp ≤55 °C ( 131°F )
CONFORMS TO:
UL 61010-1
ISA 12.12.01
CERTIFIED TO:
CSA C22.2 NO. 61010-1
CSA C22.2 NO. 213

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.
Aztec, 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,
misuse, 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 other 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 otherwise, including any implied warranties or conditions of
merchantability, quality or fitness are hereby excluded and, SureFire shall not be liable for any
loss, cost or damages, of any kind whatsoever, 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 liability shall continue to be enforceable
between the parties notwithstanding termination of the within 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‐300DESCRIPTION

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:
 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.
Enclosure

7
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.

8
BMS‐300DESCRIPTION

Graphic Overlay
The overlay has status codes printed on the face. The overlay is used for interfacing with the system and
acquiring troubleshooting information.
LED Indicator Status
GREEN 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 igniter is on.
Blinking - Indicates an igniter failure.
BLUE LED ON - Indicates stage 1 solenoid and/or actuator is opening
LED Indicators
The circuit boards LEDs illuminate through the lid of the enclosure. The LEDs indicate the following:

9
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
DOWN Arrow -Decreases the current value
High Temp -Displays High Temperature setting
Low Temp -Displays Low Temperature setting
FST -Displays current flame sensor threshold value
Igniter Volts -Displays current voltage received by the Igniter.
FR/I -Displays current flame sensing device
FR = Flame Rod I = Igniter
RTD/PS -Displays current controlling device
0 = RTD P = Alternative Sensor
ON -Turns system ON
OFF -Turns system OFF
F/C -Displays current temperature being used, Fahrenheit or Celsius.
Hours On -Displays hours of operation. Press & hold with the Up Arrow button for 5 seconds to unlock unit
Battery Volts -Displays the voltage being supplied to the unit.
Flame Strength -Displays current flame strength for the Flame Rod or Igniter.
-Hold for 5 seconds to display current solenoid timing between stage 1 and stage 2 opening.
Status Code -Displays code that corresponds with the current unit status.
-Hold for 5 seconds to display current Pilot Mode.
1 - Intermittent Pilot 2 - Standing Pilot
A/S -Displays Ignition Attempts & successful Ignitions .
-Hold for 5 seconds to display Flame Proof Timing.

10
COMPONENTDESCRIPTION

SureFire FT-Series Ignition Units
The SureFire BMS-300 is compatible with any of the FT series
igniters. Each unit is designed for specific
Applications.
Piloted System
FT-1 Systems are designed for long life in burner
applications as a pilot. The FT-1 series offers
flame sensing through the igniter or flame rod.
NOTE: Please consult local SureFire Field Tech Support for
proper pilot placement proper orifice sizing selection.
FT-1-S:
The unit above is utilizing the Igniter
as a flame sensing mechanism.
Optional Flame Sensors
Flame Rod
 Nichrome flame rod rated 2600°F
 Armored wiring harness to 1000°F duty / 1500°F flash
 Enclosed fire tube service
 Direct termination to BMS-300 controller
Igniter
 Utilizes ohms resistance reading to verify flame
 Capable of enduring high temperatures
 Direct termination to BMS-300 controller
FT-1-SF:
The unit above is utilizing a Flame
Rod 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 flame sensing.
 FT-2 Systems are suitable for pilotless 1”
burner applications, rated at 125,000btu/H
 FT-4 Systems are suitable for pilotless 2”
burner applications, rated at 500,000btu/H
 FT-6 Systems are suitable for pilotless 3”
burner applications, rated at 1,000,000but/H
NOTE: Please consult local SureFire Field
Tech Support for proper pilot placement and
proper orifice sizing selection.
FT-2-AF:
The unit above is utilizing a Flame Rod as
a flame sensing mechanism.
FT-4-AF (above) and FT-6-AF (below):
These two units are utilizing a
Flame Rod as a flame sensing mechanism.

12
COMPONENTDESCRIPTION

1in. SureFire Solenoid Valve
Part #: 51900605
 The 1in. SureFire solenoid valve is a fail closed device,
meaning if power is lost, the unit defaults to a closed state.
 1” NPT X 1” NPT connection, full port
 No adjustment necessary! Simple 2 wire termination.
 Applications include– pilotless single stage, non-venting
fuel trains, and flares.
12 Volt SureFire Actuator
Part #: 51901065
 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.
 Applications include– pilotless single stage operations ,
non-venting fuel trains, and flare systems.
1/4 in. ASCO Solenoid Valve
Part #: 51900601
 The 1/4 in. ASCO solenoid valve is a fail closed device,
meaning if power is lost, the unit defaults to a closed state.
 1/4” NPT X 1/4” NPT connection
 No adjustment necessary! Simple 2 wire termination.
 Applications include– direct pilot control valve (#72 ori-
fice) and pneumatic valve operation.


13
COMPONENTDESCRIPTION

Pressure Switch
Part #: 51901001
 The pressure switch can be used to:
 Sense loss of fuel gas and initiate system shut
down
 Sense if gas is being vented and initiate system
shut down.
 1/4” NPT X 1/2” NPT connection
 Provide operation flexibility: switch can be set
as normally open or normally closed.
Resistance Temperature Detector
 Used to detect the process temperature.
 Temperature range is 0°F — 528°F.
 Simple three wire termination.
 1/2” NPT X 1/2” NPT connection
 Available in the following sizes: 5”, 6”, 9”, 12”,
and 18”.
Please Contact SureFire for appropriate product part number.
Slow Flow Valve
Part #: 51901043
 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.

14
INSTALLATIONGUIDE

Enclosure Installation
1. The enclosure is to be mounted on a pole or a
building that is capable of supporting 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.
MounngHardware
UnistrutClamp
Unistrut
WARNING: Before any welding is attempted, disconnect all wires going to the circuit
board. Any damage caused by welding to your SureFire is NOT covered under warranty.
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

4-20mA
The proper connection method for the 4-20mA remote cir-
cuit monitoring is as follows
1. Ensure there is no power to the BMS-300 or PLC be-
fore connecting the wires.
2. Connect positive side of the power supply from the
remote monitoring equipment to port 5 and the negative
wire to port 4.
3. If a 1-5 V signal is desired instead of the 4-20m, please
install a 250 Ωresistor (at the remote monitoring
equipment) to the return in the 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 Ωresistor
(return wire).
NOTE: Scale accordingly: 4mA = 0°F/-17°C
Scale accordingly: 20mA = 529°F/ 276°C
WARNING: Deviation may produce
undesired results and damage to the
circuit board.
Run Status
1. Make the connections from the RTU/PLC to the Run
Status terminals (Port 4-5)
NOTE: The terminals are left un-touched if not used.
NOTE: Please see operation table on page 37.
PLC/ScadaConnection
Remote ON / Remote OFF
1. Terminate connections from the RTU/PLC at the Remote
ON terminals (Ports 13-14) and Remote OFF terminals
(Ports 15-16)
NOTE:The remote ON / OFF receives a signal from a
momentary switch from the PLC/SCADA to turn
unit ON / OFF remotely.
NOTE: During a Shutdown error, unit cannot be reset
remotely.

16
INSTALLATIONGUIDE

Solenoid Valve
1. Ensure supply gas is shut off.
2. Locate the instrument gas supply line controlling the
main burner control valve.
3. Cut the 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 GREEN wire short and cap it off with a wire nut
as this will not be used.
6. Use the proper conduit and connectors; wire the
solenoid valve to the SureFire system.
NOTE: Reference solenoid body for proper flow direction.
1 = Outlet 2 = Inlet
For stage 2 solenoid reference
block J6, terminals 3 and 4.
RTD
1. Install the RTD into the provided thermo-well on the vessel.
2. Connect the two negative wires to the negative terminals 10 and 11 on the circuit board.
3. Connect the one positive wire to the positive terminal 12.
NOTE: Software version 3.3 and above. When system recognizes temperature at 4ºF or less a 30 minute
timer starts. If system does no recognize a temperature increase above 4ºF, the system will shutdown on
code 18.

17
INSTALLATIONGUIDE

Standby
1. Install a switching device in one of the assigned
terminal (Ports 17-18, 23-24 & 27-28)
2. If a switching device is not installed, place a jumper in
the assigned terminal.
NOTE: Closed Contact = Normal Operation
Open Contact = Failed Operation
NOTE: Standby does not require a local reset to re-start
system.
Shutdown
1. Install a switching device in one of the assigned
terminal (Ports 19-20 & 25-26)
2. If a switching device is not installed, place a jumper
in the assigned terminal.
NOTE: Closed Contact = Normal Operation
Open Contact = Failed Operation
NOTE: Shutdown requires a local reset to re-start system.

18
INSTALLATIONGUIDE

Battery
1. Install a 12VDC SLA battery within an enclosure
separate of the BMS-300 enclosure.
2. Make the connection from the positive side of the
battery to the positive terminal (port 36)
3. Make the connection from the negative side of the
battery to the negative terminal (port 35)
4. Install a 10 Amp rated circuit breaker/ disconnect switch
inline between the battery/solar panel and the circuit
board for an accessible disconnect of power.
NOTE: If battery is more than 10 feet away from SureFire
controller, use larger wire as needed.
NOTE: If utilizing 12 VDC power supply, set voltage @ 13.4
VDC. Power supply should be rated for 90 + watts.
Solar Panel
1. Install 12 VDC Solar Panel and mount facing southeast.
2. Make the connection from the positive side of the Solar Panel
to the positive terminal (port 34)
3. Make the connection from the negative side of the Solar
Panel to the negative terminal (port 33)
NOTE: If using a 24 VDC power supply, use the Solar Panel port not
the 12V DC port.
NOTE: 75 Watt solar panel is the maximum allowable solar panel size.
NOTE: Requires internal regulator to trickle charge 12 VDC
battery.
Proof of Valve Closure
1. Install a main burner valve with a switch to provide proof of
closure and terminate at ports 21 & 22.
2. If not used, place a jumper in the assigned terminal.
NOTE: Do Not use as a Shutdown

19
INSTALLATIONGUIDE

For proper FT unit positioning, contact tech support @ 505-333-2876
Or the local SureFire representative
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 and are capable to handle high temperatures encoun-
tered in burner tubes. Terminate wires to ports 31 and 32.
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
designated port on upper left hand corner of the circuit
board. Terminate to port 3 on the J5 block.
 Flame sensing switch needs to be on Flame Rod.
NOTE: Earth grounding is required when using a flame rod. Please
check for proper grounding by connecting a multi-meter between
the nozzle and the ground lug on the circuit board..
 For igniter flame sensing terminate the two white igniter
wires to the designated ports. Terminate to ports
31 & 32.
 Flame sensing switch needs to be on Igniter.
NOTE: Reference fig. 1 on page 23 for flame sensing switch.

20
INSTALLATIONWIRINGDIAGRAM
