Surefire BMS-300 User manual

PROUDLY MADE IN THE USA
INSTALLATION & OPERATIONS
MANUAL

2
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.
This apparatus is suitable for use in Class 1, Division 2, Groups C and D, T6 Hazardous (Classified) and Ordi-
nary Location.
The system monitors target temperature with an enhanced RTD circuit; and indicates temperatures from 0°F to
490°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 fail safe run status alarm function allows for remote monitoring for environmental and
regulatory compliance. Standard remote features include temperature indication, remote ON and OFF utilizing
an RTU or PLC, and Modbus read only communication through 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: SureFire FT-series ignition units, solenoid valves, resistance temperature detectors (RTD),
flame sensors, pressure switches, and actuator valves.
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
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
SureFire Ignition Units 10-11
Additional Components 12-13
Installation Guide 14-19
Installation Wiring Diagram 20
Fuel Train Diagram 21
Controller Setup 22-29
Operation Guide 30-31
Operation / Flow Chart: Piloted and Pilotless System 32-37
Specifications 38
Basic Troubleshooting 39-43
Modbus Information 44-52
BMS-300 Software Versions 53
Contact Information & Manual Version 54
TABLEOFCONTENT

4
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, modèle HE721A0500
Operation - 40°C ( - 40°F ) ≤
Amb. Temp ≤55 °C ( 131°F )
CONFORMS TO:
UL STD 61010-1
ISA STD 12.12.01
CERTIFIED TO:
CSA STD C22.2 NO. 61010-1
CSA STD C22.2 NO. 213
CERTIFICATIONSANDWARNINGS

5
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,
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.
WARRANTY

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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
BMS‐300DESCRIPTION

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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.
BMS‐300DESCRIPTION

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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:
BMS‐300DESCRIPTION

9
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
Flame Sensor
Threshold
-Displays current flame sensor threshold value
Igniter Volts -Displays current voltage received by the Igniter.
Flame Sensor -Displays current flame sensing device
FL = 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.
-Hold for 5 seconds to display current EHTD
FSV
Solenoid Timing
-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
Pilot Mode
-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
FPT
-Displays Ignition Attempts & successful Ignitions .
-Hold for 5 seconds to display Flame Proof Timing.
BMS‐300DESCRIPTION

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SureFire FT-Series Ignition Units
The SureFire BMS-300 is compatible with any of the FT series igniters.
Each unit is designed for specific fire tube applications and comes with
an armored wiring harness for enduring high temperature protection.
The SureFire FT series ignition unit have been designed for two appli-
cation: Piloted or Pilotless systems for ease of installation.
Piloted System
FT-1 Ignition units are designed for piloted application and offered
with two flame sensing device: igniter or flame rod. The FT-1 Ignition
unit is used in a piloted application with burners from 125,000BTU/HR
to 10MM BTU/HR.
FT-1-S:
The unit above is utilizing the Igniter
as a flame sensor.
Optional Flame Sensors
Flame Rod
 Kanthal flame rod rated 2600°F
 Armored wiring harness to 500°F duty / 800°F flash
 Direct termination to BMS-300 controller
Igniter
 Utilizes ohms resistance reading to verify flame
 Armored wiring harness to 500°F duty / 800°F flash
 Direct termination to BMS-300 controller
FT-1-SF:
The unit above is utilizing a Flame
Rod as a flame sensor.
NOTE: Please consult local SureFire Field Tech Support for proper pilot placement and flame sensing
selection.
COMPONENTDESCRIPTION

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Pilotless System
FT-2, FT-4, and FT-6 Ignition units are designed for
pilotless application and offered with a flame rod flame
sensing. Optional: Thermocouple flame sensing.
 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
Optional Flame Sensors
Flame Rod (Recommended)
 Kanthal flame rod rated 2600°F
 Armored wiring harness to 500°F duty / 800°F flash
 Direct termination to BMS-300 controller
Thermocouple (Optional)
 Thermocouple rated 2400°F
 Armored wiring harness to 500°F duty / 800°F flash
 Alternate termination to BMS-300 controller
FT-2-AF:
The unit above is utilizing a Flame Rod as
a flame sensor.
FT-4-AF (above) and FT-6-AF (below):
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.
COMPONENTDESCRIPTION

12
1in. & 2in. 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.
12 Volt, 1in. 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.
COMPONENTDESCRIPTION
Please Contact SureFire for appropriate product part number.
Additional Components

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1/4 in. ASCO Solenoid Valve
 Fail closed device.
 No adjustment necessary.
 Simple termination and installation.
 Applications include– direct pilot (#72 orifice) and pneumatic valve
operation.

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
1/2in. Resistance Temperature Detector
 Detects the process temperature.
 Temperature range is 0°F — 850°F.
 Simple three wire termination.
 Available in: 5”, 6”, 9”, 12”, and 18”.
1/4in. 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 too.
COMPONENTDESCRIPTION
Please Contact SureFire for appropriate product part number.
Additional Components

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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 to the enclosure
4. Installation must comply with the national 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 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.
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.
NOTE: SureFire Actuator 1 @ Terminal block 1
SureFire Actuator 2 @ Terminal block 2
SureFire Actuator 3 @ Terminal block 3
NOTE: Must use SureFire Actuator valve or an actuator
approved by SureFire.
INSTALLATIONGUIDE

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.
1-5 Volt
1. If a 1-5 volt signal is desired instead of the 4-20mA.
2. Ensure there is no power to the BMS-300 or PLC before terminating any wires.
3. Connect the positive wire from the remote monitoring
equipment to port 5.
4. Install a 250 Ω resistor in series with the negative wire
and ground. Monitor the DC voltage signal at port 4.
NOTE:
4-20mA Scale: 4mA = 0°F/-17°C — 20mA = 529°F/ 276°C
1-5V Scale: 1 Volt = 0°F/-17°C — 5 Volt = 529°F/ 276°C
WARNING: Deviation may produce
undesired results and damage the
circuit board.
Run Status
1. Terminate wires from the RTU/PLC to the Run
Status terminals (Port 6 & 7).
NOTE: The terminals are left un-touched if not used.
NOTE: Please see operation table on page 31.
PLC/ScadaConnection
Remote ON / Remote OFF
1. Terminate wires from the RTU/PLC to 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.
INSTALLATIONGUIDE

16
Solenoid Valve
1. Ensure main supply gas is shut off.
2. Locate the pilot gas supply line and instrument gas
supply line controlling the main burner control valve.
3. Install solenoid or solenoids in the appropriate location
for piloted or pilotless application.
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.
NOTE: See page 21 for solenoid location on fuel train for
piloted and pilotless application.
NOTE: Solenoid proper flow direction.
Reference: 2 = Inlet and 1 = Outlet
For piloted application use stage 1 &
stage 2 solenoid terminals
RTD
1. Install the RTD into the provided thermoweld on
the vessel for process temperature.
2. Connect negative (-) wires to terminals 10 and
11.
3. Connect positive (+) wire to terminal 12.
Note: Software version 3.3 and above. When system recognizes temperature at 4ºF or less, press ON
and a 30 minute timer starts. If system does no recognize a temperature increase above 4ºF, the system
will shutdown on code 18.
For pilotless application use
stage 1 solenoid terminal
INSTALLATIONGUIDE

17
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
system.
Shutdown
1. Install a normally open or normally close dry contact
device in one of the assigned terminal (Ports 19-20 &
25-26)
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: Shutdown requires a local reset to re-start system.
INSTALLATIONGUIDE
Proof of Valve Closure
1. Install a main burner valve with a normally close dry
contact device to provide proof of closure and termi-
nate wires at ports 21 & 22.
2. If no device is used, a jumper needs to be in place at
the assigned terminal
NOTE: Do Not use as a Shutdown

18
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 white wires that are not polarity sensitive. Terminate
wires to ports 31 and 32.
4. Flame Sensor wires need to be terminated as described below.
For proper FT unit positioning, contact tech support @ 505-333-2876 or the local SureFire representative
Flame Sensing
Flame sensing mechanism will be dependent on the ignition unit being
utilized.
FLAME ROD:
 For flame rod flame sensing terminate flame rod wire
at designated port on upper left hand corner of the cir-
cuit board. Terminate to port 3 on the J5 block.
 Flame sensing switch needs to be on Flame Rod.
 Isolated grounding is required. Terminate ground
wire to circuit board labeled Earth 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.
IGNITER:
 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.
INSTALLATIONGUIDE

19
Battery
1. Install a 12VDC SLA battery within an enclosure
separate of the BMS-300 enclosure.
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
VDC. Power supply should be rated for 90 + watts.
Solar Panel
1. Install 12 VDC Solar Panel
2. Connect negative (-) terminal to port 33
3. Connect positive (+) terminal to port 34
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 35 & 36
INSTALLATIONGUIDE

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INSTALLATIONWIRINGDIAGRAM