Surefire BMS-300 User manual

PROUDLY MADE IN THE USA
INSTALLATION & OPERATIONS
MANUAL

2
 TableofContents: 2
 Introduction: 3
 Certification and Warnings: 4
 Warranty and Return Policy: 5
 BMS-300 Description: 6-9
 SureFire Ignition units: 10-11
 SureFire Additional Components: 12-13
 Installation Guide: 14-18
 Specifications: 19
 Run Status and Flame Strength Information: 20
 Diagrams: 21-22
 BMS-300 Setup: 23-28
 Sequence of Operation: 29-34
 Troubleshooting Guide: 35-37
 Modbus Information: 38-45
 SoftwareVersions: 46
Table of Contents

3
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
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,
T6 Hazardous (Classified) and Ordinary Location.
The system monitors target temperature with an enhanced RTD circuit and detects
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.
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-300 System Introduction

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Suitable for use in Class I, Division 2,
Groups C, D, T6 Hazardous
(Classified) and Ordinary Location
CERTIFIED TO:
CSA STD C22.2 NO. 61010-1
CSA STD C22.2 NO. 213:2017 Ed.3
*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 MATE-
RIEL 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 MATE-
RIALS USED IN THE FOLLOWING DEVICES: Panasonic Relay, Model JW2SN-DC12V, and Ham-
lin Relay, Model HE721A0500
*AVERTISSEMENT*
L'exposition à certains produits chimiques peuvent dégrader les FERMETURE PROPRIETES des maté-
riaux utilisés dans les appareils suivants: Panasonic 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
UL STD 121201:2017 Ed.9
Certifications and Warnings

5
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.
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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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 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 certification:
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 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 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.
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
AMBER LED ON - Indicates igniter is on.
Blinking - Indicates an igniter failure.
BLUE LED ON - Indicates stage 1 solenoid and/or actuator has opened
LED Indicators:
The circuit boards LEDs illuminate through the lid of the enclosure. The LED’s indicate the following:
BMS-300 Description

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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 Displayed Value / Functional Operation
Up Arrow  Increases the current value. Press & hold with the Hours On button for 5 seconds to unlock
the system.
Down Arrow  Decreases the current value
High Temp  Displays High Temperature setpoint
Low Temp  Displays Low Temperature setpoint
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 setpoint
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 the listed FT series igniters.
Each unit is designed for specific fire tube applications and comes with an
armored wiring harness suitable for high temperature application. The
SureFire FT series ignition units have been designed for both piloted and
pilotless applications.
Piloted System:
The FT-1 Ignition units are designed for piloted application with igniter or
flame rod flame sensing devices. The FT-1 Ignition units are used in a
piloted application with burners ranging from 125,000BTU/HR to 10MM
BTU/HR.
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
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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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.
Flame Rod:
 Kanthal flame rod rated 2600°F
 Armored wiring harness to 500°F duty / 800°F flash
 Direct termination to BMS-300 controller
For proper pilotless ignition unit and orifice sizing, contact tech support @ 505-333-2876 or the local
SureFire representative
SureFire Ignition Units

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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.
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.
SureFire Additional Components

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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
1/2” Resistance Temperature Detector:
Detects the process temperature.
Simple three wire termination.
Available in: 5”, 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
SureFire Additional Components

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SureFire BMS-300 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 ensure 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 FT unit in fire tube.
3. The igniter has two white wires that are not polarity sensitive. Terminate wires to ports 31 & 32. See
illustration below.
For proper FT unit positioning, contact tech support @ 505-333-2876 or
the local SureFire representative
Flame Rod Flame Sensing:
Piloted and Pilotless ignition units are wired the same as below.
1. Terminate flame rod wire at designated port on upper left hand corner of the
circuit board. Terminate to port 3 on the J5 block.
2. Isolated grounding is required. Terminate ground wire to circuit board
labeled Earth Ground and ground screw on GUA on arrestor housing.
3. Flame sensing switch needs to be on Flame Rod.
NOTES:
 Please do not bond the flame sensing ground to
facility ground to avoid flame sensing disruption.

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Piloted System:
1st and 2nd Stage 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 1st stage solenoid down stream of the pilot regulator.
4. Install 2nd stage solenoid in the appropriate location to actuate the
main burner control valve.
5. Cut and bend custom 3/8” tubing and connect to tubing fittings on
solenoids.
6. Terminate 1st and 2nd stage solenoid wires.
NOTES:
 ASCO Solenoid proper flow direction: 2 = Inlet and 1 = Outlet
Installation Guide
Pilotless System:
SureFire Actuator Valve & 1st Stage Solenoid Valve
1. Ensure main supply gas is shut off.
2. Locate the pilot gas supply line and eliminate the pilot fuel train completely.
3. Install the SureFire Actuator Valve in the fuel train on the main burner line down steam of the main
burner control valve.
4. Locate the instrument gas supply line controlling the main burner control valve and install 1st stage
solenoid in the appropriate location to actuate the main burner control valve.
5. Cut and bend custom 3/8” tubing and connect to tubing fittings on the solenoid valve.
6. Terminate 1st stage solenoid wires to ports 8 & 9. See notes and termination location on page 17.
7. Terminate Actuator wires at terminal block labeled Actuator Valve (1, 2 & 3) from the Actuator Valve
terminals (1, 2 & 3).

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RTD:
1. Install the RTD into the provided thermowell on
the vessel for process temperature.
2. Connect negative (-) wires to terminals 10 & 11.
3. Connect positive (+) wire to terminal 12.
NOTES:
 Software version 3.3 and above. When system recognizes temperature at 4ºF or less, press ON button
and a 30 minute timer starts. If system does no recognize a temperature increase above 4ºF, the system
will shutdown on code 18. Repeat until temperature gets above 4ºF.
Installation Guide
Pilotless System:
SureFire Actuator Valve & 1st Stage Solenoid Valve
NOTES:
 Terminal block 1 @ SureFire Actuator port 1
 Terminal block 2 @ SureFire Actuator port 2
 Terminal block 3 @ SureFire Actuator port 3
 Must use a SureFire Actuator valve or an actuator
approved by SureFire.
 ASCO Solenoid proper flow direction: 2 = Inlet and 1 =
Outlet
Standby Switches:

1. If no device is used, a jumper is required on ports 17
& 18, 23 & 24, and 27 & 28
2. When using a device, install a normally open or
normally close dry contact device and terminate wires
from the device in one of the assigned terminal (Ports
17 & 18, 23 & 24, and 27 & 28)
NOTES:
 Closed Contact = Normal Operation
 Open Contact = Failed Operation
 Standby does not require a local reset to re-start
system.

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Shutdown Switches:
1. If no device is used, a jumper is requires on ports 19
& 20 and 25 & 26.
NOTES:
 Closed Contact = Normal Operation
 Open Contact = Failed Operation
 Shutdown requires a local reset to re-start system.
Installation Guide
Proof of Valve Closure:
1. If no device is used, a jumper is required on ports 21
& 22.
2. Terminate wires at ports 21 & 22 from the set of
contacts on the main burner control valve.
NOTE:
 Do not use ports as a standard Shutdown
4-20mA Output:
The proper connection method for the 4-20mA / 1-5 Volt remote circuit monitoring is as follow.
4-20mA:
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 Ωresistor in series with the negative wire and ground. Monitor the DC voltage signal at port
4.
NOTES:
 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.

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Installation Guide
Run Status:
The proper connection method for the Run Status is as
follow.
1. Terminate wires from the RTU/PLC to the Run
Status terminals (Port 6 & 7).
Remote ON / Remote OFF:
The proper connection method for the Remote ON / OFF is as follow:
1. Terminate wires from the RTU/PLC to the Remote ON terminals (Ports 13 & 14)
2. Terminate wires from the RTU/PLC to the Remote OFF terminals (Ports 15 & 16)
NOTES:
 The remote ON / OFF receives a signal from a
momentary switch from the PLC/SCADA to turn
unit ON / OFF remotely.
 During a Shutdown error, unit cannot be reset
remotely.
12 VDC Battery Input:
1. Install a 12VDC SLA battery within an enclosure that is
separate from 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 Input:
1. Install 12 VDC Solar Panel on a pole or build and face it south.
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.

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Specifications
Power Supply Specifications
Battery Volts 11-15 VDC
12 VDC Power Supply SET @ 13.4 VDC, 10 Amps
Solar Panel 12 VDC Type Solar Panel
Max System Amperage 7.8 Amps / 0.6 Amps Avg.
Ignition Unit Specifications
Igniter Current Draw 7.5 Amps Inrush, 2.0 Amps NOM (during
Sensor Specifications
RTD Range 0°F — 529°F
ALT Sense Input Dry Contact Switch (Open / Close loop)
Standby or Shutdown Inputs Dry Contact Switch (Open / Close loop)
Remote ON/OFF Inputs Dry Contact Switch (Open / Close loop)
Note: No voltage or current should be applied to the dry contact ports above.
Output Specifications
4-20mA 12-24 VDC for 4-20mA Output
Status 12-24 VDC @ 0.5 Amps
Max Volts: 26 VDC, Max Current: 0.5 Amps
Relay Specifications
Stage 1 Solenoid Load 12 VDC, 60 Watt MAX
Stage 2 and ALT Solenoid Load 12 VDC, 60 Watt MAX
Actuator Valve Load 12 VDC, 60 Watt MAX
Other
Fuses: F1, F2, and F3 5 Amps
Fuses: F4 and F5 10 Amps

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Run Status Operational States:
Status Red LED
Open ON
Open OFF
Close OFF
Open Blinking
Green
LED
OFF
ON
ON
OFF
Blue
LED
OFF
OFF
ON
OFF
Operational State
System OFF or Manual
System ON, Pre-purge
complete, igniter on
Flame sensed, Burner
running, No Errors
Shutdown, Igniter Error
Amber
LED
OFF
ON
OFF
Blinking
Standby Error Open OFF Blinking OFF OFF
Shutdown Error Open Blinking OFF OFF OFF
Flame Strength Value Information:
Flame Rod No Flame Present Flame Present
Flame Strength Value Above 500 Below 6
Run Status and Flame Strength Information
Igniter No Flame Present Flame Present
Flame Strength Value Between 7-12 Between 12-40