Surefire iBURNER BMS-100 User manual

Proudly Made in
the USA
PROUDLY MADE IN THE USA
INSTALLATION & OPERATIONS
MANUAL

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 Table of Contents: 2
 Introduction: 3
 Certification and Warnings: 4
 Warranty and Return Policy: 5 - 6
 BMS-100 Description: 7 - 10
 SureFire Ignition Units: 11 - 12
 SureFire Additional Components: 13 - 14
 Installation Guide: 15 - 18
 Specifications: 19
 Run Status, Alarm Out and Flame Strength: 20
 Diagrams: 21-24
 BMS-100 Setup / Menu: 25 - 28
 Sequence of Operation: 29 - 32
 Troubleshooting Guide: 33 - 36
 Daughter Board Information: 37
 Modbus Information: 38 - 41
Table of Contents

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The BMS-100 is designed as a pilot maintainer for Flare, Combustor or Fire Tube applications
within the Oil and Gas Industry. The BMS-100 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
power and is solar ready with a specific solar power termination port.
This Burner Management System is suitable for use in
Class 1, Division 2, Groups C and D or unclassified locations.
The BMS-100 monitors a pilot flame utilizing Type K thermocouple. The SureFire controller
controls and monitors both the pilot and main burner valves as required. Flame failure
shutdowns, alarm functions, high temperature shutdown and other features allow this system to
operate as a fail safe system. The SureFire BMS-100 and ignition unit packages provides
solutions for environmental and regulatory compliance. Additional option adder cards are
available with Modbus communication, data logging, 4-20ma input control and high
temperature safety shutdown.
Every SureFire system must pass complete factory QA/QC inspections before shipment.
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.
BMS-100 System Introduction

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*WARNING*
EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR
CLASS I, DIVISION 2, GROUPS C AND D, OR UNCLASSIFED APPLICATIONS;
*MISE EN GARDE*
RISQUE D’EXPLOSION - LA SUBSTITUTION DE COMPOSANTS PEUT ALTÉRER APTITUDE
POUR LA CLASSE I, DIVISION 2, GROUPES C ET D OU DES APPLICATIONS DE UNCLASSIFED ;
*WARNING*
EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN
SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS;
*MISE EN GARDE*
EXPLOSION DE DANGER - NE DÉBRANCHEZ PAS L’ÉQUIPEMENT À MOINS QUE LE POUVOIR
A ÉTÉ ÉTEINTE OU L’ENVIRONNEMENT EST CLASSÉ NON DANGEREUX;
*WARNING*
EXPOSURE TO SOME CHEMICALS MAY DEGRADE THE SEALING PROPERTIES OF MATERIALS
USED IN THE FOLLOWING DEVICES: HAMLIN ELECTRONICS RELAY, MODEL HE721A0500,
ALLIED ELECRONICS RELAY, MODEL JW2SN-DC12V, AND PANASONIC RELAY, MODEL
DS2E-SL2-DC5V
*MISE EN GARDE*
L’EXPOSITION À CERTAINS PRODUITS CHIMIQUES PEUT-ÊTRE DÉGRADER LES PROPRIÉTÉS
DE L’ÉTANCHÉITÉ DES MATÉRIAUX UTILISÉS DANS LES APPAREILS SUIVANTS : RELAIS
ÉLECTRONIQUE LIN, MODÈLE HE721A0500, ALLIÉES ÉLECTRONIQUE, MODÈLE JW2SN-DC12V
ET RELAIS DE PANASONIC, MODÈLE DS2E-SL2-DC5V
SUBSTITUTION DES ÉLÉMENTS SUIVANTS PEUT ALTÉRER
*WARNING*
SUBSTITUTION OF THE FOLLOWING COMPONENTS MAY IMPAIR SUITABILITY FOR DIVISION
2
*MISE EN GARDE*
LES QUALITÉS DE DIVISION 2
Reference Designation Description Type of Protection
K1, K2, or K3 Relay Sealed Contacts
Certifications and Warnings

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Warranty and Return Policy
SureFire Warranty Statement:
SureFire warrants all equipment of its own manufacture to be free of defects in material and workmanship.
SureFire’s sole obligation hereunder shall be expressly limited to repair or exchange, F.O.B. Farmington,
NM, USA of such defective equipment, but 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 original manufacturer’s or vendor’s
warranty.
The warranty policy is related to manufacturing defects. The return policy is related to the return of product
for any reason other than manufacturing defects. Returns must be approved by SureFire in advance of
shipment and returned products must be in their original condition. Restocking fees for returns are at the
discretion of SureFire and may vary by product.
Shipping Cost:
For Warranty Claims, the shipping cost incurred by shipping the product from the customer to SureFire will
be at the expense of the customer. If the product is deemed under warranty by SureFire, then the shipping
cost incurred by shipping the product from SureFire to the customer will be at the expense of SureFire. If the
product is deemed non-warranty by SureFire, then the shipping cost incurred by shipping the product from
SureFire to the customer will be at the expense of the customer.
For Return Claims, the shipping cost will be at the expense of the customer.
Product Description Warranty Policy
Defective Products
Return Policy
Customer Return New Product
SureFire Controllers:
BMS-300, BMS-100, Flare-100
and BMS-350 Controllers 3 Years from date of purchase 180 Days from date of purchase 20% Minimum Restocking Fee
SureFire FT Ignition Units:
FT-1, FT-2, FT-4, FT-6 and
FTL-F Ignition Units 2 Years from date of purchase 180 Days from date of purchase 20% Minimum Restocking Fee
Additional Components Manufacturers carry own individual warranty policy on
Components.
Manufacturers carry own
individual return policy on
Components.

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Warranty and Return Policy
Warranty Claims Resolution:
SureFire will provide one of the following resolutions for warranty claims.
The resolution will be completed at the sole discretion of SureFire.
1. SureFire will repair any defective parts, free of charge to the customer.
2. SureFire will replace the defective product, free of charge to the customer.
SureFire will provide a credit, minus a restocking fee for approved return claims.
Voiding SureFire’s Warranty:
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.
Conducting product repairs, parts exchange or unauthorized maintenance will immediately void the SureFire
warranty.
Non-Warranty Products:
In the event that a product is returned to SureFire under a warranty claim, and SureFire deems the product
non-warranty, the following options are available on a case by case basis:
1. If the product is able to be repaired, SureFire may offer a quotation for the repair costs.
2. If the product is not able to be repaired, SureFire may either discard the damaged product or return the
damaged product to the customer, upon customer consent.
3. A replacement product may be purchased.
Return Material Authorization:
To acquire a return material authorization from SureFire, it is highly recommended to contact the SureFire
technical support hotline @ 505-333-2876 for potential troubleshooting.
If technical support deems that product in need of a warranty or returns claim, please contact the SureFire
returns department @ 505-333-2878 Ext. 18 or @ [e-mail].

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Enclosure:
The SureFire BMS-100 system uses a polycarbonate NEMA 4X Enclosure to house the circuit board. The
Graphic overlay, with 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 and has been tested to the following to meet certifications:
 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.
BMS-100 Description

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BMS-100 Circuit Board:
The SureFire BMS-100 System is controlled by state of the art, non-arcing, electronics that monitor and
control all burner functions. It comes with 2 LED indicators and a LED display. It also comes with individual
terminal blocks and power connector to ease wiring and installation.
BMS-100 Description

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Graphic Overlay:
The overlay is used for interfacing with the system to acquire system data. The overlay also provides a list of
status codes and a display window that shows data, settings and information.
BMS-100 Description
LED Indicators:
The circuit boards LEDs illuminate through the lid of the enclosure. The LED’s indicate the following:
LED Indicator Status
GREEN LED ON - Indicates that the system is on and operating properly
Blinking - Indicates a standby switch has been activated
RED LED ON - Indicates that the system is off
Blinking - Indicates a shutdown switch has been activated

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5 Button Keypad:
The SureFire BMS-100 System has a 5 button Key Pad to control and monitor the system.
The buttons perform the following functions:
BMS-100 Description
Button Displayed Value / Functional Operation
On
 Press once (while in locked mode) - Turns the system On
 Press once (while in unlocked mode) - Accepts new setpoint or
setting selection within the menu system
Off
 Press once (while in locked mode) - Turns the system Off
 Press and hold (while in locked mode) - Unlocks the system
 Press and hold (while in unlocked mode) - Lock the system
Status Code /
Up Arrow
 Press once (while in locked mode) - Displays the current system
status code
 Press once (while in unlocked mode) - Increases the selected value
Battery Volts
 Press once (while in locked mode) - Displays the current supply
voltage to the BMS
 Press once (while in unlocked mode) - Enters the selected mode or
selection to allow setting or setpoint adjustment
Flame Value /
TC HTS
 Press once (while in locked mode) - Displays current flame strength
value of the ignition unit’s flame sensing device
 Press and hold (while in locked mode) - Displays the current
temperature value of the high temperature safety thermocouple
 Press once (while in unlocked mode) - Decreases the selected value

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SureFire FT-Series Ignition Units:
The SureFire BMS-100 is compatible with the listed FT series
igniters. Each unit is designed for specific Flare, Combustor and
Fire Tube applications. The FT series ignition units have been
designed for both piloted and pilotless applications.
Flare / Combustor Pilot System:
The FTL-F series Ignition units are designed for Flare and
Combustor applications, utilizing thermocouple as a flame sensor.
Piloted System:
The FT-1 Ignition units are designed for piloted applications,
utilizing the igniter or thermocouple flame sensing device. The
FT-1 Ignition units are used in a piloted application with burners
ranging from 125,000 BTU/HR to 10 MM BTU/HR.
Optional Flame Sensors:
Thermocouple
 Utilizes temperature reading to verify the presence of a flame
 Armored wiring harness rated to 1000°F duty and 1500°F flash
 Direct termination to the BMS-100 Controller
SureFire Ignition Units
For proper pilot placement and flame sensing selection, contact SureFire Tech Support @
505-333-2876 or the local SureFire representative

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SureFire Ignition Units
Pilotless System:
The FT-2, FT-4 and FT-6 Ignition units are designed
for pilotless applications with a flame rod flame
sensing device. These three ignition units are used in
pilotless fire tube applications for horizontal treaters
with the following BTU/HR burner ratings.
 FT-2 Systems (1”) are rated for 125,000BTU/HR
 FT-4 Systems (2”) are rated for 500,000BTU/HR
 FT-6 Systems (3”) are rated for 1,000,000BTU/HR
The FT-4-VT and FT-6-VT ignition units are designed
for pilotless applications for vertical treaters and have
the same BTU/HR burner ratings as above.
Thermocouple
 Utilizes temperature reading to verify the presence
of a flame
 Armored wiring harness rated to 1000°F duty and
1500°F flash
 Direct termination to the BMS-100 Controller
For proper pilotless ignition unit and orifice sizing, contact tech support @ 505-333-2876 or the local
SureFire representative

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SureFire Additional Components
1” SureFire Actuator:
 Control the main fuel gas to the main burner.
 Factory programmed and pre-wired so no adjustment is
necessary.
 3 wire termination.
 Proof of valve closure switch kit available
 Applications include– non-venting pilotless fuel trains,
double block fuel trains, fuel trains for combustors and
flare systems.
1” & 2” SureFire Solenoid Valve:
 Fail-closed device.
 No adjustment necessary.
 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.

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SureFire Additional Components
1/4” ASCO Solenoid Valve:
 Fail closed device.
 No adjustment necessary.
 Simple termination and installation.
 Applications include– direct pilot (#72 orifice) and
pneumatic valve operation.
1/2” 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
Thermocouple, Type K:
 Detects the process temperature.
 Simple two wire termination.
 Available in: 6”, 9” and 12”.
1/4” 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.
 Recommended for piloted installations

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SureFire BMS-100 Enclosure:
1. The enclosure is to be mounted on to 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 to the enclosure.
4. Installation must comply with the national electric code.
WARNING:
 Before any welding is attempted, disconnect all wires going to the circuit board. Any damage caused by
welding to the SureFire BMS is NOT covered under warranty.
 Before terminating any wires, be sure no power is supplied to the controller.
 Any damage caused by standing on or using the enclosure as a step is NOT covered under warranty.
Installation Guide
SureFire FT-Series Ignition Unit:
1. Ensure supply gas is turned off and locked out / tagged out
2. Install the SureFire pilot ignition unit.
3. The igniter has two white wires that are not polarity sensitive, terminate wires to
terminals (ports 27 & 28).
4. Thermocouple wires need to be terminated as described below.
Flame Sensing:
1. For thermocouple flame sensing terminate the red (-) wire at port
5 and the yellow (+) wire at port 4 (See Fig. 3) and position the
switch on thermocouple.
Warning:
The Flame Sensing Switch must be placed
in proper position before power is applied
to circuit board. Do not switch mode while
circuit board is powered up.

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Installation Guide
2nd Stage Valve Control:
SureFire Actuator Valve:
1. Install a SureFire Actuator Valve in the fuel train on the main vent line to the combustor.
2. Terminate wires on terminal block labeled Actuator Valve (1, 2 & 3) from the Actuator Valve
terminal ports (1, 2 & 3).
NOTES:
 SureFire Actuator 1 @ Terminal block 1
 SureFire Actuator 2 @ Terminal block 2
 SureFire Actuator 3 @ Terminal block 3
 Must use SureFire Actuator valve or an actuator
 approved by SureFire.
SureFire Solenoids:
1. Install a SureFire 1” or 2” Solenoid Valve in the fuel train on
the main vent line to the combustor.
2. Terminate solenoid wires on ports 1 & 3 on Actuator Valve
terminal block. Port 2 is not used.
1st Stage Valve Control:
1. Ensure main supply gas is shut off.
2. Locate the pilot gas supply line.
3. Install a 1/4” ASCO or 1” SureFire solenoid valve in the
appropriate location in the pilot fuel train.
4. Cut and bend custom 3/8” tubing and connect to tubing fittings on
solenoid.
5. Terminate solenoid wires at the Solenoid Valve terminals port 8 & 9.
NOTES:
 ASCO Solenoid proper flow direction: 2 = Inlet and 1 = Outlet

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Installation Guide
ESD and Shutdown Interlock:
1. If ports are not used, a jumper is required on ports 21 &
22 and 23 & 24.
2. When using a device, install a normally open or close dry
contact device, terminate wires from device in one of the
assigned terminals.
NOTES:
 Closed Contact = Normal Operation
 Open Contact = Failed Operation
 Shutdown requires a local reset to re-start system.
Loss of Fuel Gas and Spare Standby:
1. If ports are not used, a jumper is required on ports 17 & 18 and 19 & 20.
2. When using a device, install a normally open or close dry
contact device, terminate wires from device in one of the
assigned terminals.
NOTES:
 Closed Contact = Normal Operation
 Open Contact = Failed Operation
 Standby does not require a local reset to re-start system.
Alarm Out and Run Status:
The proper connection method for the Alarm Out and Run
Status is as follow:
1. Terminate wires from the RTU/PLC to the Alarm out
terminal (Ports 6 & 7).
2. Terminate wires from the RTU/PLC to the Run Status
terminals (Ports 15 & 16).
NOTES:
• The above ports are left un-touched if not used.

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Installation Guide
Remote ON and Remote OFF
The proper connection method for the Remote ON or Remote OFF is as
follows:
1. Terminate wires from the RTU/PLC to the Remote ON
terminals (Ports 11 & 12).
2. Terminate wires from the RTU/PLC to the Remote OFF
terminals (Ports 13 & 14).
NOTES:
 The remote ON / OFF receives a signal from a momentary switch (closed
loop) from the PLC/SCADA to turn unit ON or OFF remotely.
 During a Shutdown error, unit cannot be reset remotely using the Remote
ON.
Solar Panel :
1. Install 12 VDC Solar Panel.
2. Connect negative (-) terminal to port 29.
3. Connect positive (+) terminal to port 30.
NOTES:
 Maximum rating for solar panel is 75 watts
 Circuit board has internal charge controller to charge 12 VDC battery, if a
battery is connected to port 31 & 32
Battery
1. Install a 12VDC SLA battery within an enclosure separate of
the SureFire enclosure.
2. Connect negative (-) terminal to port 31.
3. Connect positive (+) terminal to port 32.
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 VDC.
Power supply should be rated for 90 + watts.

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Specifications
Power Supply Specifications
Battery Volts 12 - 13.4 VDC
12 VDC Power Supply Set @ 13.4 VDC
Solar Panel 12 VDC / 75 W
Max System Amperage 5.0 Amp / 0.6 Amp Avg.
Ignition Unit Specifications
Ignition Unit @ Inrush 6.5 Amps
Ignition Unit @ Steady State 2.0 Amps Nominal (during ignition only)
Sensor Specifications
Standby and Shutdown Switches Dry Contact Switch (Open / Close Loop)
Remote ON and Remote OFF Dry Contact Switch (Open / Close Loop)
Battery / Igniter Wiring Requirements
16 AWG 10 foot length - Copper Stranded
14 AWG 20 foot length - Copper Stranded
12 AWG 30 foot length - Copper Stranded
Relay Specifications
Stage 1 Solenoid Valve Load 12 VDC, 60 Watt MAX
Actuator Valve Load 12 VDC, 60 Watt MAX
Other
Fuses: F3 and F5 10 Amps

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Unit Status Run Status Green LED Red LEDAlarm Out
Manual OFF Open OFF ONOpen
Shutdown Open OFF BlinkingOpen
Standby Open Blinking OFFClosed
Unit ON
(Status Code 00) Closed ON OFFClosed
Run Status and Alarm Out Operational States:
Run Status, Alarm Out and Flame Strength
Flame Strength Value Information:
Thermocouple No Flame Present Flame Present
Open Flare
Thermocouple Value < 300°F > 350°F
Combustor
Thermocouple Value
20% Decrease
(If value < 800°F)
or
40% Decrease
(If Value > 800°F)
Increase of 20°F