Surefire iBURNER BMS-100 User manual

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

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The BMS-100 system is designed to operate in Combustor and Flare applications in the Oil and Gas Industry.
The BMS-100 system utilizes the SureFire FTL series, FT-1-S, FT-1-ST, and FTL-FFG units to provide igni-
tion.
The controller’s display is designed to operate in ambient temperatures from – 40⁰F to 131⁰F, 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 LED’s, and contains a status code chart that is printed on the overlay to pro-
vide assistance in troubleshooting. The unit requires 12 VDC or 24 VDC power, and is solar ready with a spe-
cific solar power termination port.
This apparatus is suitable for use in Class1, Division 2, Groups C and D, or unclassified locations.
The BMS-100 detects a flame utilizing the igniter or thermocouple as the flame sensing device. Once the igni-
tion flame makes contact with the igniter or thermocouple, a signal is sent to the BMS-100 and the unit regis-
ters a flame. The BMS-100 also provides 2nd stage solenoid and actuator valve timing control after flame is
proven.
The BMS-100 also comes with an adder daughter board that allows 4-20mA input and high temperature safety
shutdown. Plus a USB data logging port to log pilot flame with real time and date stamp.
The BMS-100 contains relighting capability, providing the combustors and flare application with more oppor-
tunity to re-ignite the fuel gas.
Every SureFire system will pass complete factory QA/QC testing.
Also available is a control solenoid valve, Actuator valve, Standby Pressure Switches and FT ignition unit.
We are dedicated to providing quality American made safety control systems for Combustor and Flare Appli-
cations. The system has been developed through thousands of hours of critical design, engineering, and field
testing.
INTRODUCTION

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Certifications and Warnings 4
Warranty Statement 5
BMS-100 Description
Enclosure 6
Circuit Board 7
Graphic Overlay 8
LED Indicators / Keypad Functions 9
Component Description
SureFire Ignition Units 10
Additional Components 11
Installation Guide 12-15
Installation Wiring Diagram 16
Fuel Train Diagram 17-19
Operation Guide 20-21
Operation Guide: Sequence of Operation / Flow Chart 22-27
Specifications 28
Troubleshooting Guide 29-32
Daughter Board Information and Installation______________________________________________33-35
Daughter Board Setup________________________________________________________________36-37
Installation Notes 38
BMS - 100 Software Versions 39
Contact and Version Info 40
TABLE OF CONTENT

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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;
WARNING
EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN
SWITCHED OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS;
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
WARNING
SUBSTITUTION OF THE FOLLOWING COMPONENTS MAY IMPAIR SUITABILITY FOR
DIVISION 2
Reference Designation Description Type of Protection
K1, K2, or K3 Relay Sealed Contacts
CERTIFACTIONS AND WARNINGS
Rated Input Voltage: 12VDC
Wattage: 60.0 MAX/ 7.2 AVG
Amperage: 5.0 amps MAX/0.6 amps AVG
Class 1, Division 2, Groups C and D, or Unclassified Applications, T4
Ambient Temperature Range: -40°F ≤Tamb ≤131°F (-40°C ≤Tamb ≤55°C)
Certified to:
UL 61010 - 1
UL 61010 –2 030
ISA 12.12.01

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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.
WARRANTY

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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 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.
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 con-
trol all combustor and flare applications. It comes with 2 LED indicators and a status code LED display.
BMS-100 DESCRIPTION

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Graphic Overlay
The overlay provides the list of status codes on the face. The overlay is used for interfacing with the system
and acquiring troubleshooting information.
BMS-100 DESCRIPTION

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5 Button Keypad:
The SureFire BMS-100 has a 5 button keypad to assist in controlling and monitoring the system.
Note: Secondary functions can only be adjusted, when system is unlocked. Pre-purge time and timing
between ignition attempts is now the same.
Button Functions
Turns the unit ON.
Turns the unit OFF.
Primary: Displays the code that corresponds with the current unit status.
Secondary: Press button for 5 seconds to unlock the system.
Tertiary: Up arrow - Increments settable value for pre-purge & safety T/C limit.
LED Indicators
The circuit board LEDs illuminate through the lid of the enclosure. The LEDs indicate the following:
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
BMS-100 DESCRIPTION
Primary: Displays the current battery voltage.
Secondary: Press button for 5 seconds to display current pre-purge timing.
To set pre-purge timing: Unlock system, press & hold Battery Volts button & use
the up arrow button to set timing. Range: 01 - 10 minutes pre-purge time.
Primary: Displays the current flame strength value for the igniter or T/C.
Secondary: Press for 5 seconds to display current safety T/C limit.
To set safety T/C limit: Unlock system, press & hold T/C HTS button & use the
up arrow button to set limit. Range: 100°F - 2400°F.

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FTL-U Flare Pilot
The FTL-U are stainless steel, straight style pilots for open flare appli-
cations. It utilizes the igniter element to sense the pilot flame.
 FTL-U flare pilot is custom to each application, max length on 1”
nipple is 6’-0”.
 Pilot nozzle and igniter assembly are easily field replaceable.
SureFire FTL-U and FT-Series Ignition Unit.
The SureFire BMS-100 is compatible with any of the Flare Pilots ignition
units designed for combustor and flare applications and certain FT-Series
ignition units designed for firetube applications.
Optional Flame Sensors
Igniter
 Utilizes ohms resistance reading to verify flame
 Armored wiring harness to: 500°F duty / 800°F flash
 Direct termination to BMS-100 controller
Thermocouple
 Utilizes temperature reading to verify flame
 Armored wiring harness rated to:
1000°F duty / 1500°F flash
 Direct termination to the BMS-100 controller
FT-1-ST (above)
The unit above is utilizing a Thermocouple as
a flame sensing mechanism.
FT-1-S (above)
The unit above is utilizing the Igniter Element
as a flame sensing mechanism.
COMPONENT DESCRIPTION
FT-1 Series Ignition Unit
The FT-1 series ignition unit is a aluminum block with a stainless steel
nozzle for firetube application. It utilizes the igniter or thermocouple to
sense the pilot flame.
FTL-F Flare Pilot
The FTL-F are stainless steel, straight pilots for open flare application.
It utilizes a thermocouple to sense the pilot flame.
 FTL-F flare pilot are reliable ignition system for flare applications.
 Thermocouple and igniter element are easily field replaceable.
FTL-F FTL-U

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Pressure Switch
Part #: 51901001
 Used on a variety of standbys and shutdowns.
 Can be used as normally open or normally closed.
 Adjustable from 2psi — 12psi.
1/4 in. ASCO Solenoid Valve
Part #: 51900601
 Fail closed device.
 No adjustment necessary.
 Simple termination and installation
 Application include - Combustor and Flare systems.
12 Volt, 1in. SureFire Actuator
Part #: 51901065
 Controls the main fuel gas to the main burner.
 Factory programmed and pre-wired so no adjustment is necessary.
 3 wire termination.
 Applications include - Combustor and Flare systems.
1in. & 2 in. SureFire Solenoid Valve
1” Part #: 51900605
2” Part #: 51900605-2
 Fail closed device.
 No adjustment necessary.
 Simple termination and installation.
 Applications include - Combustors and Flare
systems.
COMPONENT DESCRIPTION

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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 at the enclosure.
4. Installation must comply with the local electric code.
Mounng Hardware
Unistrut Clamp
Unistrut
2nd Stage Valve Control
SureFire Actuator / Solenoid Valve
1. Install the SureFire Actuator or Solenoid Valve in the
fuel train for the vent or main line.
2. When an Actuator is being utilized. Terminate wires on
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.
3. When a solenoid is being utilized. Terminate solenoid
wires on ports 1 & 3 on Actuator Valve terminal block.
Port 2 is not used. See Fig. 1.
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

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PLC/Scada Connection
The proper connection method for the Alarm Out, Remote On,
Remote Off 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 Remote ON
terminals (Ports 11-12) and Remote OFF terminals (Ports
13-14)
NOTE: The remote ON / OFF receives a signal from a
momentary switch (closed or open loop) from the
PLC/SCADA to turn unit ON / OFF remotely.
NOTE: During a Shutdown error, unit cannot be reset remotely.
3. Terminate wires from the RTU/PLC to the Run Status
terminals (Ports 15-16)
NOTE: These terminations are left un-touched if not used.
NOTE: The above ports are dry contacts and no voltage or
current should be applied to them.
1st Stage Valve Control
Solenoid Valve
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. Use proper connectors and conduit for wiring.
6. Terminate solenoid wires at the Solenoid Valve
terminals (port 8-9)
NOTE: See pages 17, 18 and 19 for solenoid location on fuel
trains for combustors and flares.
NOTE: Solenoid proper flow direction.
Reference ASCO: 2 = Inlet and 1 = Outlet
INSTALLATION GUIDE

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Standby
1. Install a normally open or normally close dry contact
device in one of the assigned terminals (Ports 17-18 &
19-20)
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 terminals (Ports 21-22 &
23-24)
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.
SureFire FTL or FT-1 Series Ignition Unit
1. Ensure all supply gas is turned off and locked out /
tagged out
2. Install the FT unit in the flare or combustor.
3. The igniter has two white wires that are not polarity
sensitive and terminate wires to terminals (ports 27 & 28).
4. Flame Sensor wires need to be terminated as described on page 15.
INSTALLATION GUIDE

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Flame Sensing Switch (Igniter or
Thermocouple)
Flame sensing mechanism will be dependent on the ignition
unit being utilized. Ensure proper flame sensing mode has been
selected. See Fig.1
 For Igniter flame sensing, the igniter wires terminate at
ports 27 & 28 and position switch on igniter.
 For thermocouple flame sensing terminate the red (-) wire
at port 5 and the yellow (+) wire at port 4 and position
switch on thermocouple.
NOTE: Switch must be placed in proper position before power
is applied to circuit board. Do not switch while circuit
board is powered up.
Fig. 1
Solar Panel / 12 or 24 VDC Power Source
1. Install 12 VDC Solar Panel or a 12V / 24V DC power source
2. Connect negative (-) terminal to port 29
3. Connect positive (+) terminal to port 30
NOTES:
 Maximum rating for solar panel is 75 watts
 When using 24 VDC, amps are limited, max current is 75 watts
or 3 amps (Current limiting device is recommended)
 Circuit board has internal charge controller to charge 12 VDC
battery, if a battery is connected to port 31 & 32
 When using a 12VDC power source, output voltage needs to be
set at
14VDC.
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. See page 28.
 If utilizing 12 VDC power supply, set voltage @ 13.4
VDC. Power supply should be rated for 90 + watts.
INSTALLATION GUIDE

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INSTALLATION WIRING DIAGRAM

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1” SureFire Solenoid Fuel Train
1” SOLENOID FUEL TRAIN

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1” SureFire Solenoid / Actuator Fuel Train
1” SOLENOID / ACTUATOR FUEL TRAIN

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1/4” ASCO Solenoid / 3PG Valve / Actuator Fuel Train
1/4” SOLENOID / 3PG / ACTUATOR FUEL TRAIN

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Run Codes Description
00 System Running
01 Purge Before Start-up
04 5 Second Alarm
05 Igniter On
Standby Codes Description
06 Spare Standby
07 Loss of Fuel Gas Standby
08 Flame Sense Countdown
Shutdown Codes Description
11 Manual / Remote Shut Off
12 Max Retries Exceeded
13 Low Battery Voltage
14 Igniter Disconnected
15 Igniter Short
16 Shutdown Interlock
17 ESD Activated
18 Replace FT-Ignition Unit
19 T/C Flame Sensor Error or Disconnected
20 Solenoid Short
21 Solenoid Disconnected
22 Safety T/C High Temp. Shutdown
23 Safety T/C Error or Disconnected
Status Code
OPERATIONS GUIDE