Surefire iBURNER BMS-100, BMS-100 Installation & Operation Manual

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Page 1

Proudly Made in

the USA

INSTALLATION & OPERATIONS

PROUDLY MADE IN THE USA

MANUAL

Page 2

INTRODUCTION

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 ignition.

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 provide assistance in troubleshooting. The unit requires 12 VDC or 24 VDC power, and is solar ready with a specific 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 ignition flame makes contact with the igniter or thermocouple, a signal is sent to the BMS-100 and the unit registers 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 opportunity 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 Applications. The system has been developed through thousands of hours of critical design, engineering, and field testing.

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TABLE OF CONTENT

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

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Certified to:

UL 61010 - 1

CERTIFACTIONS AND WARNINGS

UL 61010 –2 030

Rated Input Voltage: 12VDC

ISA 12.12.01

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)

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

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WARRANTY

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.

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BMS-100 DESCRIPTION

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.

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.

WARNING:

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BMS-100 DESCRIPTION

BMS-100 Circuit Board

The SureFire BMS-100 system is controlled by state of the art, non-arcing electronics that monitor and control all combustor and flare applications. It comes with 2 LED indicators and a status code LED display.

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BMS-100 DESCRIPTION

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.

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BMS-100 DESCRIPTION

LED Indicators

The circuit board LEDs illuminate through the lid of the enclosure. The LEDs indicate the following:

LED Indicator Status

GREEN

RED

LED ON - Indicates that the system is on and operating properly

Blinking - Indicates a standby interlock is activated

LED ON - Indicates that the system is off

Blinking - Indicates a shutdown failure or interlock has been activated

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

Turns the unit ON.

Turns the unit OFF.

Functions

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.

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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COMPONENT DESCRIPTION

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.

FTL-U Flare Pilot

The FTL-U are stainless steel, straight style pilots for open flare applications. 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.

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.

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.

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

The unit above is utilizing the Igniter Element

FTL-F

FT-1-S (above)

as a flame sensing mechanism.

FTL-U

 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.

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COMPONENT DESCRIPTION

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.

1/4 in. ASCO Solenoid Valve

Part #: 51900601

 Fail closed device.

 No adjustment necessary.

 Simple termination and installation

 Application include - Combustor and Flare systems.

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.

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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.

Unistrut

Unistrut Clamp

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

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.

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.

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INSTALLATION GUIDE

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

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INSTALLATION GUIDE

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.

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INSTALLATION GUIDE

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.

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INSTALLATION WIRING DIAGRAM

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1” SOLENOID FUEL TRAIN

1” SureFire Solenoid Fuel Train

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1” SOLENOID / ACTUATOR FUEL TRAIN

1” SureFire Solenoid / Actuator Fuel Train

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1/4” SOLENOID / 3PG / ACTUATOR FUEL TRAIN

1/4” ASCO Solenoid / 3PG Valve / Actuator Fuel Train

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Status Code

Run Codes Description

OPERATIONS GUIDE

Standby Codes Description

Shutdown Codes Description

System Running

Purge Before Start-up

5 Second Alarm

Igniter On

Spare Standby

Loss of Fuel Gas Standby

Flame Sense Countdown

Manual / Remote Shut Off

Max Retries Exceeded

Low Battery Voltage

Igniter Disconnected

Igniter Short

Shutdown Interlock

ESD Activated

Replace FT-Ignition Unit

T/C Flame Sensor Error or Disconnected

Solenoid Short

Solenoid Disconnected

Safety T/C High Temp. Shutdown

Safety T/C Error or Disconnected

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OPERATIONS GUIDE

Run Status

The Run Status (Ports 15-16) is a open/closed contact switch. The Run Status can be terminated at the RTU/

PLC device and provide remote monitoring of the unit.

Unit Status Run Status GREEN-LED RED-LED

Manual OFF Open OFF ON

Shutdown Open OFF Blinking

Standby Open Blinking OFF

Unit ON

Closed ON OFF

(Status Code 00)

Alarm Out

The Alarm Out (Ports 6-7) is an open/close contact switch. The Alarm Out can be terminated at the RTU/PLC

device and provide remote monitoring of the unit.

Note: Table content below is when system is running.

Unit Status Alarm Out GREEN-LED RED-LED

Manual OFF Open OFF ON

Shutdown Open OFF Blinking

Standby Closed OFF OFF

Unit ON

(Status code 00)

Closed ON OFF

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OPERATIONS GUIDE - SEQUENCE OF OPERATION

Ignion Process with out Daughter Board

1) Press the ON Button

2) Pre-purge - Pre-purge countdown displayed. Green LED ON.

3) Audible Alarm - 5 second countdown displayed. Green LED ON.

4) Igniter - 8 second countdown displayed. Green LED ON

5) Solenoid valve opens - Igniter remains on for another 5 seconds. Green LED ON.

6) Ignition is achieved and a 30 second flame proof timing begins. Pilot ignites. Green LED ON.

7) Flame is sensed, flame proof timing countdown expires, the display reads “On” (Status code 00). Green LED ON.

8) 30 second timer begins before actuator valve opens (count down not visible).

9) After 30 seconds the actuator valve opens.

Re-Ignion Process - Flame Out

1) Once the system recognizes that no flame is sensed, the system will automatically begin the re-ignition

process.

2. Reference step 2 - 7 in the “Ignition Process Section”

Re-Ignion Process - Standby

1) System in standby. Blinking Green LED.

2) Once the System resolves the Standby issue, the system will automatically begin the re-ignition process

3) Reference step 2- 7 in the “Ignition Process Section”

Re-Ignion Process - Shutdown

1) The System requires manual reset in the event of a shutdown

2) System in shutdown. Blinking Red LED.

3) Once the Shutdown issue has ben resolved, press the OFF button then ON button to reset.

4) Reference step 2 - 7 in the “Ignition Process Section”

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OPERATIONS GUIDE - FLOW CHART

Flowchart without Daughter Board

Page 24

OPERATIONS GUIDE - SEQUENCE OF OPERATION

Ignion Process with Safety T/C (Daughter board installed)

1) Press the ON Button

2) Pre-purge - Pre-purge countdown displayed. Green LED ON.

3) Audible Alarm - 5 second countdown displayed. Green LED ON.

4) Igniter - 8 second countdown displayed. Green LED ON

5) Solenoid valve opens - Igniter remains on for another 5 seconds. Green LED ON.

6) Ignition is achieved and a 30 second flame proof timing begins. Pilot ignites. Green LED ON.

7) Flame is sensed, flame proof timing countdown expires the display reads “T/C temperature value” (Status code 00). Green LED ON.

8) Thermocouple temperature is observed.

Re-Ignion Process - Flame Out

1) Once the system recognizes that no flame is sensed, the system will automatically begin the re-ignition

process.

2. Reference step 2 - 7 in the “Ignition Process Section”

Re-Ignion Process - Standby

1) System in standby. Blinking Green LED.

2) Once the System resolves the Standby issue, the system will automatically begin the re-ignition process

3) Reference step 2- 7 in the “Ignition Process Section”

Re-Ignion Process - Shutdown

1) The System requires manual reset in the event of a shutdown

2) System in shutdown. Blinking Red LED.

3) Once the Shutdown issue has ben resolved, press the OFF button then ON button to reset.

4) Reference step 2 - 7 in the “Ignition Process Section”

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OPERATIONS GUIDE - FLOW CHART

Flowchart with Safety T/C (Daughter Board installed)

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OPERATIONS GUIDE - SEQUENCE OF OPERATION

Ignion Process with Daughter Board, Safety T/C, and 4-20mA Input

1) Press the ON Button

2) Pre-purge - Pre-purge countdown displayed. Green LED ON.

3) Audible Alarm - 5 second countdown displayed. Green LED ON.

4) Igniter - 8 second countdown displayed. Green LED ON

5) Solenoid valve opens - Igniter remains on for another 5 seconds. Green LED ON.

6) Ignition is achieved and a 30 second flame proof timing begins. Pilot ignites. Green LED ON.

7) Flame is sensed, flame proof timing countdown expires, the display reads “T/C temperature” (Status code 00). Green LED ON.

8) Thermocouple temperature is observed. Green LED ON.

9) 4-20mA pressure input is monitored. Green LED ON.

10) Actuator valve opens and closes according to 4-20mA pressure input. Green LED ON.

Re-Ignion Process - Flame Out

1) Once the system recognizes that no flame is sensed, the system will automatically begin the re-ignition

process.

2. Reference step 2 - 7 in the “Ignition Process Section”

Re-Ignion Process - Standby

1) System in standby. Blinking Green LED.

2) Once the System resolves the Standby issue, the system will automatically begin the re-ignition process

3) Reference step 2- 7 in the “Ignition Process Section”

Re-Ignion Process - Shutdown

1) The System requires manual reset in the event of a shutdown

2) System in shutdown. Blinking Red LED.

3) Once the Shutdown issue has ben resolved, press the OFF button then ON button to reset.

4) Reference step 2 - 7 in the “Ignition Process Section”

Page 27

OPERATIONS GUIDE - FLOW CHART

Flowchart with Daughter Board, Safety T/C, and 4-20mA Input

Page 28

SPECIFICATIONS

Power Supply Specifications

Device Specification

Battery 12VDC —13.4VDC

12 VDC Power Supply SET @ 13.4 VDC

Solar Panel / 24 Volt Input 12 VDC Solar Panel / 24 Volt DC Power Supply

Note: Current limitations: 7 amps @ 12 VDC and 3 amps @ 24 VDC

Solar Panel 75 WATT Maximum (Solar panel not tested by Intertek)

Ignition Unit Specifications

Device Specification

Ignition Unit @ In Rush 6.5 Amps

Ignition Unit @ Steady state 2.0 Amps nominal (During ignition only)

Max System Amperage 7.8 Amps / 0.6 Amps Avg.

Sensor Specifications

Device Specification

Standby Switches Dry Contact Switch (Open / Close loop)

Shutdown Switches Dry Contact Switch (Open / Close loop)

Remote On/Off Dry Contact Switch (Open / Close loop)

Note: No voltage or current should be applied to the ports above.

Battery / SureFire Igniter Wiring Requirements

16 AWG @ 10 ft, Copper Stranded

14 AWG @ 20 ft, Copper Stranded

12 AWG @ 30 ft, Copper Stranded

Page 29

TROUBLESHOOTING GUIDE

RUN CODES

Status Codes Symptom Action

System Running

Purge Before Start-up

5 Second Alarm

 Pilot flame is present

 No errors present

 Pilot flame not present  Normal Operation

 Pilot flame not present  System is warning operators on ignition

 Pilot flame not present  Igniter element is receiving voltage

 Normal Operation

 Display reads On or Thermocouple temper-

ature value

 60 second pre-purge countdown is displayed

attempt

 Ignition warning buzzer can be heard

(120dB)

 Igniter element temperature is increasing

Igniter On

STANDBY CODES

Status Codes Symptom Action

Spare Standby

 Pilot flame not present

 No activity when

attempting start-up

 Ports 19 & 20 are

activated

 System detecting an open circuit

 Customer supplied switch is activated

 Check switching device for faulty operation

 Verify wiring from switching device

 Verify jumper is installed

 Jumper is required if function is not being

utilized

Visual

 Green LED ON

Visual

 Blinking Green

LED

Loss of Fuel Gas

Standby

 Pilot flame not present

 No activity when

attempting start-up

 Ports 17 & 18 are

activated

 Pilot flame igniting  Normal Operation

Flame Sense Count-

down

If the present issue is not resolved by the above steps, please call

SureFire Technical Support @ 505-333-2876

 System detecting an open circuit

 Customer supplied switch is activated

 Check switching device for faulty operation

 Verify wiring from switching device

 Verify jumper is installed

 Jumper is required if function is not being

utilized

 30 second countdown is displayed

 Attempting to see if pilot flame is present

NOTE:

 Blinking Green

LED

 Green LED ON

Page 30

TROUBLESHOOTING GUIDE

SHUTDOWN CODES

Status Codes Symptom Action

 Pilot flame not present  System has been turned OFF Manually

 System has been turned OFF remotely by

Manual/Remote Shut

Off

Max Retries Exceeded

Low Battery Voltage

 Pilot flame not present

a momentary switch signal to the Remote Off terminals, ports 15&16

 Display reads OFF

 System has exceeded set number of at-

tempts without success.

 Verify proper fuel pressure, air/fuel mix-

er setting and amperage to igniter.

 Verify proper valve operation: Solenoids,

diaphragm valve, actuator valve, etc.

 Plugged orifice on pilot fuel gas

 Battery or power supply below minimum

voltage required to operate system

 Verify battery volts is 12.0 volts

 Check or replace battery if required

 Check solar panel for faulty operation

Visual

 Red LED ON

 Blinking Red

LED

 Blinking Red

LED

Igniter Disconnected

Igniter Short

 Pilot flame not present

 Check wiring installation and installation

specifications

 Igniter element could have wore out or is

broken.

 Check power supply.

 Ensure igniter wires are not touching

each other or grounding to conduit.

 Ensure there is no moisture in the con-

duit.

NOTE:

If the present issue is not resolved by the above steps, please call

SureFire Technical Support @ 505-333-2876

 Blinking Amber

and Red LED

 Blinking Amber

and Red LED

Page 31

TROUBLESHOOTING GUIDE

SHUTDOWN CODES

Status Codes Symptom Action

Shutdown Interlock

ESD Activated

Replace FT-Ignition

Unit

 Pilot flame not present

 Ports 23 & 24 are activated

 Pilot flame not present

 Ports 23 & 24 are activated

 Pilot flame not present

 System detecting an open circuit

 Customer supplied switch is activated

 Check switching device for faulty opera-

tion

 Verify wiring from switching device

 Verify jumper is installed

 Jumper is required if function is not be-

ing utilized

 System detecting an open circuit

 Customer supplied switch is activated

 Check switching device for faulty opera-

tion

 Verify wiring from switching device

 Verify jumper is installed

 Jumper is required if function is not be-

ing utilized

 Igniter Ohms exceeded 4 Ohms

 Check ohms after igniter has cooled

 Igniter has deteriorated causing high

ohms.

 Ensure proper flame sensing mode has

been selected

Visual

 Blinking Red

LED

 Blinking Red

LED

 Blinking Red

LED

 Pilot flame not present

T/C Flame Sensor

Error or Disconnected

If the present issue is not resolved by the above steps, please call

SureFire Technical Support @ 505-333-2876

 Check device for failure

 Verify wiring from device

 System detecting a disconnect upon ini-

tial start-up

 Ensure proper flame sensing mode has

been selected

NOTE:

 Blinking Red

LED

Page 32

TROUBLESHOOTING GUIDE

SHUTDOWN CODES

Status Codes Symptom Action

Solenoid Disconnected

Solenoid Short

Safety T/C High

Temp. Shutdown

Safety T/C Error or

Disconnected

 Pilot flame not present

 System detecting a disconnect

 Check device for faulty coil

 Verify wiring from device

 System detecting a short

 Check device for wire short

 Verify wiring from device

 High temperature set point reached

 System detecting a disconnect upon ini-

tial start-up

 Check device for failure

 Verify wiring from device

 If not using, check for jumper on input

 System detecting a disconnect upon ini-

tial start-up

 Check device for failure

 Verify wiring from device

 System detecting a disconnect

 If not using, check for jumper on input

Visual

 Blinking Red

LED

 Blinking Red

LED

 Blinking Red

LED

 Blinking Red

LED

If the present issue is not resolved by the above steps, please call

SureFire Technical Support @ 505-333-2876

NOTE:

Page 33

DAUGHTER BOARD PCB

Daughter Board Printed Circuit Board

The SureFire Daughter Board PCB has a USB port, USB ejection switch, 4-position dip switch, Safety T/C port, 4-20 Input port, Battery, programming port, and 2 LED lights.

 Blinking orange LED shows that USB is communicating with the Daughter Board and recording flame

strength data.

 Green LED illuminates when the “USB eject switch” is pressed to show that USB can be removed.

WARNING: Do not remove USB jump drive until green LED is on.

Dip Switch

USB Eject Switch

USB Port

Orange LED

Safety T/C Port

Jumper if not used

Battery (CR2032)

4-20mA Input Port

Green LED

Programming Port

Page 34

DAUGHTER BOARD INSTALLATION

How to attach Daughter Board on to the BMS-100:

1. There are 4 standoffs on the Daughter Board that helps the Daughter Board mount to the BMS-100. As shown in the picture below, Fig. 1.

2. Make sure when attaching Daughter Board to BMS-100, the “J4” connection faces towards and aligns with the connector on the BMS-100.

3. Place the Daughter Board on to the BMS-100 and make sure all 4 standoffs align with the holes on the BMS-100 board. Press Daughter Board down until it clicks into place. As shown in the picture below, Fig. 2.

Standoff

Fig. 1

Standoff

Connector ‘J4’

Standoff

Fig. 2

Standoffs

Page 35

DAUGHTER BOARD INSTALLATION

BMS-100 Circuit Board with Daughter Board

The SureFire BMS-100 system with the Daughter Board in place.

Daughter Board mounted on BMS-100

Page 36

DAUGHTER BOARD SETUP

Set High-Temperature shutdown value from T/C:

1. Unlock the system by holding down the “status code” button for 5 seconds.

2. Hold down the “Flame Strength” button for 5 seconds to see set-point value and press the “Status Code”

button to set high-temperature shut down value. (Default value is set to 1900°).

NOTE: The temperature will scroll quickly when button is held down. If you go past the temperature set point continue to hold the up arrow button and the display will scroll past 2400°F and re-start at 100°F again.

Shutdown Codes

Status Codes Symptom Action

Safety T/C High

 Flame reached the safety T/C

high-temperature shut down value

 Wait for T/C to cool down

Temperature

 Safety T/C is damaged

 Replace the Safety T/C

Safety T/C

Error or Disconnect

 Safety T/C is not installed.

 Jumper is not installed

 Make sure that safety T/C is installed

 Verify jumper is installed (When T/C is

not is use)

Visual

 Blinking Red

LED

 Blinking Red

LED

Page 37

DAUGHTER BOARD SETUP

4-20mA Input Dip Switch Settings

Warning: Remove power from the system when selecting dip switch setting.

NOTE: The 4-20mA input will control the actuator valve only after flame is proven.

There are 4 pre-defined settings of 4-20mA input, which controls the actuator. The table below shows the 4 different settings that can be selected.

To set up Switch 1 setting, slide the switch 1 to ON position and make sure all other switches stay in OFF position. At this setting, when the transducer sees pressure of 1.5oz, the system will turn ON the actuator valve to the open position and keeps the valve open until the pressure drops down to 0.5oz then it will close the actuator valve. See the table below.

The other 3 settings work in the same way but at different pressure levels. See the table below.

Dip Switch Settings

Dip Switch No ON OFF Dip Switch setting

Switch 1 (ON) 1.5 oz. 0.5 oz.

Switch 2 (ON) 2.0 oz. 0.5 oz.

Switch 3 (ON) 2.5 oz. 0.5 oz.

Switch 4 (ON) 3.0 oz. 1.0 oz.

Page 38

INSTALLATION NOTES

Commissioning Date:

_________________________________________________

Igniter Ohms:

_________________________________________________

Pilot Pressure:

_________________________________________________

Main Burner Pressure:

__________________________________________________

Battery Volts:

_________________________________________________

Software Version:

__________________________________________________

Controller Serial Number:

_________________________________________________

Ignition Unit Serial Number

_________________________________________________

Notes:

_________________________________________________

__________________________________________________

Page 39

SOFTWARE VERSIONS

BMS-100

Software Version Release Date Description

V1.0 9/6/2017 Standard software with 3 relight attempts.

V1.2 10/4/2017

T/C flame sensor is more sensitive on flame sensing and flame out.

BMS-100 Daughter Board

Software Version Release Date Description

V1.0 9/7/2017 Base software

Page 40

BMS-100 Installation and Operations Manual

08/21/2017

Last Update: 10/4/2017

Version 1.0

SureFire Farmington, NM Office:

2405 W. Aztec Blvd. Aztec, NM 87410 P: 505-333-2878 F: 505-333-2879

SureFire Houston, TX Office:

12510 Cutten Rd. Houston, TX 77066 P: 281-377-9756 F: 281-379-1081

Tech Support:

505- 333-2876

For SureFire Product Updates Please Visit:

www.surefire-controls.com