ENM-613-004

ENM-613-004
Burner management isn’t just
“something” we do,
Model : BMS-300
it’s ALL we do.
Serial Number __________
The Surefire BMS-300 :
The newest member of the American made SureFire family is the BMS 300. This unit
is created around a fifth generation controller built for heavy-duty service. It’s certified
to UL, ISA, & CSA standards for hazardous areas, has all the rugged dependability
you demand, and carries an outstanding Two Year Warranty. Additionally, the BMS
300 comes ready to work with the newest SureFire FT ignition units, assuring ease of
installation, and long life in burners of nearly every size.
The controller and easy to read display are designed to operate in ambient temperature from –40°F
to 130°F, and are coated for corrosion resistance. They are mounted in a NEMA 4X enclosure and
supplied wit a UV resistant keypad. Each unit also includes function indicator lights, and a code
chart printed on the front panel.
Every BMS is factory programmed for simplified one button startup with the industry leading FT
ignition units. The units require 12 VDC power, and is solar ready with an improved solar charging
regulator
The system monitors target temperature with an enhanced RTD circuit; and indicates temperatures
from 0°F to 500°F. Standard programming automatically 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 included, along with an audible startup warning. The system offers a failsafe run
status/alarm connection to monitor system status for environmental and regulatory compliance.
Standard remote features include temperature indication, remote ON and OFF using the customers
RTU and PLC.
The SureFire unit 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 a rigorous factory testing process, and is available with a
matched set of: control solenoids, resistance temperature detector (RTD), flame sensor, fuel loss
standby switch, and an FT-series ignition unit
We are dedicated to providing quality American-made safety control systems for industrial burners,
thousands of hours of critical design, engineering, and field-testing goes into every SureFire we
ship. We feel our systems are the finest available, and after using them, we are confident you’ll
agree.
ENM-613-004
2

Suitable for use in Class I, Division 2, Groups C, D,
T6 Hazardous (Classified) and Ordinary Location

Operation - 40oC ( - 40oF ) ≤ Tamb ≤ 55 oC ( 131oF )
4001406
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 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 MATERIALS USED IN THE FOLLOWING DEVICES: 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: Panasonic
Relais, modèle JW2SN-DC12V, et Hamlin Relais, modèle HE721A0500
CERTIFIED TO:
CSA C22.2 NO. 199-07
CSA C22.2 NO. 61010-1
CSA C22.2 NO. 213
ANSI Z21.20—2007
UL 372—2007
ENM-613-004
CONFORMS TO:
CSA E 60730-1 (ANNEX H)
UL 61010-1
ISA 12.12.01
3
Contents Overview
Page 6
Product Testing/ Control Pollution
Page 7
Introduction
Page 8
Applications and Options
Page 9
Standard Components
Page 10-15
Enclosure
Circuit Board
LED Indicators
Status Code Display
Graphic Overlay
16 Button Keypad
FT Ignition Unit
Resistance Temperature Detector
Low Watt Explosion Proof Solenoid
Pressure Switch
Slow Flow Valve
Optional Components
AC to DC Converter or UPS
Base Sparkless Igniter
Operation and Setup
High and Low Process Temperatures
Flame Sensor Type
Flame Sensor Threshold (FST)
Flame Strength
Igniter Voltage
Input Signal
Power Supply
Attempt and Ignition Counter
Hours On Counter
Fahrenheit and Celsius
Viewing the Current Status Code
Optional Modes
Status Code Definitions
Startup Procedure for FT-1
Operation Flow Charts
ENM-613-004
Page 10
Page 10
Page 11
Page 11
Page 11
Page 12
Page 13
Page 14
Page 14
Page 15
Page 15
Page 16
Page 16
Page 16
Page 17-24
Page 17
Page 18
Page 18
Page 19
Page 20
Page 20
Page 20
Page 21
Page 21
Page 22
Page 22
Page 22
Page 23
Page 24
Page 25-26
Flow Chart Using Sense to Start System
Page 25
Flow Chart Using RTD Control
Page 26
4
Installation
Page 27-36
Enclosure
Page 28
FT-1 Ignition Unit
Page 29
RTD (Resistance Temperature Detector)
Page 30
4-20mA Remote Temperature Integration
Page 31
Solenoid Valve
Page 32
Slow Flow Valve
Page 33-34
Fuel Pressure Switch
Page 34
Actuator Valve
Page 35
Power
Page 36
Notices
Page 37
Wiring
Page 38
Wiring Diagram
Drawings
Page 38
Page 39-40
Fuel Train P&ID, “Single Stage”
Page 39
Fuel Train P&ID, “Two Stage”
Page 40
Inputs and Outputs
Page 41-43
Troubleshooting Guide
Page 44-47
Specifications
Page 50
Installation and Setup Notes
Page 52-53
ENM-613-004
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Contents—Overview
This manual provides information specific to the SureFire BMS-300 Burner Management System.
Other equipment used in conjunction with the SureFire System is supplied with its own instructions, to be referred to for proper operation and installation.
It is essential that this manual be read and understood for proper installation and operation of
the SureFire BMS-300 Burner Management System.
THE SUREFIRE BMS-300 MANUAL IS ORGANIZED AS FOLLOWS:
Introduction &
Descriptions
SureFire BMS-300 Burner Management System, its features and
components.
Operation
Proper operation and use of the SureFire BMS-300
Installation
How to install the SureFire BMS-300 and its components.
Troubleshooting
Describes quick problem solving techniques
Specifications
Describes system physical and operational characteristics and limits.
The information in this document is subject to change without notice. SureFire, LLC makes no
representation or warranties with respect to the contents hereof.
IMPORTANT
NOTE: Only qualified personnel should install and maintain this product
NOTE: Please read, become familiar with, and follow this manual and all applicable safety and
electrical regulations before attempting to install this product.
HAZARD CLASSIFICATION INSTALATION: Please adhere to any and all regulations required for
installing products in such Hazardous Locations as defined for electrical equipment.
BEST PRACTICE: Adhere to all applicable code.
BEST PRACTICE: PROPER GROUNDING OF THE SUREFIRE EQUIPMENT IS REQUIRED FOR
CORRECT OPERATION.
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Product Testing and Control Pollution Situation
IMPORTANT
THE BMS-300 was tested and approved at the following parameters
Temperature tested at Min = -40C°/-40F°
Temperature tested at Max = 55C°/131F°
11/08/2006
11/09/2006
CAUTION: Do not place the unit in a location where unit will be exposed to temperatures beyond the tested and approved temperature ranges without additional protection
NEMA 4X Enclosure

Windblown dust protection

Water Damage
Rain, Sleet, Snow Splashing and Directed Water

Corrosion protection

External formation of ice protection
IP66 Certified

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 effect
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Introduction
The SureFire Burner Management System is purpose built to
automatically control a natural draft or atmospheric burner. The systems
are particularly designed to meet the needs of the oil and gas industry,
but may be implemented where appropriate for a wide variety of
industrial processes.
SureFire is a completely automated and preprogrammed Burner
Management System that:
1.
2.
3.
4.
Is user friendly
Improves safety
Decreases emissions
Lowers cost
Our Burner Management Systems are designed to help send more gas
down the sales line, and less emissions into the environment .
Where other igniter systems will typically use some variation of spark
ignition. SureFire has discovered that spark ignition systems require
extensive maintenance and regular replacement of the igniters. Whereas
SureFire manufactures the only purpose built system that offers and
completely sparkless ignition unit. As a result of this unique ignition
process, SureFire is better suited to handle the harsh duty and safety
demands placed on the industrial process environments around the
globe.
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Application and Options
The SureFire BMS-300 System will automatically and safely control the ignition and operation of gas
fired naturally aspirated burners. It will monitor the process at all times and shut off gas flow in a flame
failure situation, or if the high temperature limit is reached, or if any other monitored situation is detected
as unsafe. Ignition retries are automated and system will attempt to relight three times on a flame failure
before shutting down and alarming out. Alarm out requires manual reset to resume normal operation.
The unit can be placed into a standby, when the standby s cleared, the unit will resume normal operation. The settings and programming are stored in a non-volatile memory, and will retain with loss of power or reset. The system is designed with fail safe architecture and will provide run status indication. If an
error occurs in the system, theBMS-300 will shutdown, and a red LED will blink, indicating a shutdown
state.
Some examples of applications in which The SureFire BMS-300 is used are :








Separators
Tanks
Dehydrators
Line Heaters
Treaters
Reboilers
Incinerators
Combustors
The following components are available for the SureFire BMS-300:

SureFire BMS-300 Control System, & Control keypad tested and mounted in NEMA 4X Enclosure

FT Series Ignition Unit with SureFire Sparkless Igniter

Resistance Temperature Detector—Platinum—(RTD)

12 Volt, Low Watt, 3-way, Explosion Proof Solenoid Valve/s fitted with exhaust screens.

Loss of Gas Pressure Standby Switch

AC-DC UPS (Un-interruptible Power Supply)

Base SureFire Sparkless igniter

Slow Flow Valve for smooth and consisted main burner ignition
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Controller Description
1. Enclosure
The SureFire BMS-300 System uses a fiberglass NEMA 4X enclosure to house the circuit board, and
keypad overlay. The graphic overlay with membrane keypad is mounted on the exterior door of the
enclosure and tested in conjunction with the controller circuit board prior to shipment to ensure quality.
2. 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.
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Controller Description
3. LED Indicators
On the front side of the circuit board there are 4 status indicator LED lights that indicate the following:
LED Indicator
GREEN
Status
Solid indicates system is ON and is Operating properly
Blinking indicates a standby interlock is activated
RED
Solid indicates system is OFF
Blinking indicates a shutdown failure or interlock is activated
AMBER
Solid indicates Igniter Is On
Blinking indicates an Igniter Failure
BLUE
Solid indicates that the Main Burner is running
4. Status Code LED Display
The Status Code LED Display is a 4 Digit 7 Segment unit that displays; current temperature, status
codes, setup codes, programming functions, and parameters for the system.
5. Graphic Overlay
The graphic overlay has commonly used status codes printed on the face, and is the interface for
programming, setup and manually operating the unit. Below is an illustration :
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Controller Description
6. 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 or DISPLAYS
Up Arrow
Increases the temperature setting, flame sensor threshold or changes
a function
Down Arrow
Decreases the temperature setting, flame sensor threshold or
changes a function
High Temp
High Temperature setting
Low Temp
Low Temperature setting
FST
Flame Sensor Threshold value
H.S.I. Volts
Voltage being sent to the Igniter
CAD/FR
Flame sensor type being used
( FR=FLAME ROD , CAD=CAD EYE )
RTD/PS
Input control signal in use
(RTD=RTD , PS=Alt Sense)
ON
System ON
OFF
System OFF
Status Code
Code that corresponds with the current unit status
Hold status code button for 5 seconds to adjust operational modes:
1 is intermitten mode
2 is standing pilot mode
A/S
Ignition Attempts and Successful Ignitions (A = attempts,
S = Successful ignitions). Hold for 5 seconds to adjust flame proof
timing
°F/°C
Changes Temperature from (F=Fahrenheit to C=Celsius)
Hours On
How long the system has operated in hours
Battery Volts
Voltmeter reading power supply or battery Voltage
Flame Strength
Strength of the Flame as read by the current
Flame Sensor. Hold for 5 seconds for solenoid timing adjustment
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Component Description
1. SureFire FT-Series Ignition Units
The SureFire BMS-300 is offered standard with your choice of SureFire FT– series ignition unit. These
proprietary ignition unit eliminate the most common installation and startup issues, as well as adding
considerable longevity. They have become the standard for all SureFire systems. These FT units are
purpose built for size selected burner installations and will not function with a Cad Eye. The FT-series
ignition units are pre-assembled and factory tested.
The FT-series feature a high endurance flame rod,
pilot nozzle, and a flow enhanced sparkless igniter
Selecting your System:
FT-1 Systems are designed for long life in burner
applications as a pilot
FT-2 Systems are suitable for pilotless 1” burner
applications, rated @ 125,000btu/H
FT-4 Systems are suitable for pilotless 2” burner applications, rated @ 500,000btu/H
FT-6 Systems are suitable for pilotless 3” burner applications, rated @ 1,000,000but/H
TIPS:
Install your FT-Series ignition unit with the flame rod toward the top, or on the side of a traditional burner, for incinerator, combustor and flare applications this is not necessary
FT-1 Best Practice: FT-1 ignition unit is a direct replacement upgrade for existing pilot nozzles, in SureFire controlled burners rated @ or > 125,000btu/H. Regardless of preexisting pilot nozzle alignment,
final FT-1 nozzle alignment should always be behind the main out flame edge of the main burner, not
within the main burner flame itself. The FT-1 is designed for use in conjunction with a 1/2” pilot duty,
Wenco-style Venturi mixer with a standard #72 orifice (.025”)
FT-2, FT-4and FT-6 Best Practice: FT-2 FT-4 and FT-6 ignition unit is a direct replacement for existing
burner nozzles, in applications eliminating the pilot, and is tested and recommended for appropriately
sized burner mixer.
Best Practice: Installation of FT-Series ignition units as a retrofit/upgrade to existing SureFire installations is a upgrade as it enhances reliability and provides years of trouble free operation
Nipple Length Best Practice:
For 1” burner applications, a 8” nipple is recommended
For 2” burner applications, a 16” nipple is recommended
For 3” burner applications, a 24” nipple is recommended
Failure to provide the proper nipple length may result in internal burning of the FT units, therefore causing damage to the unit.
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Component Description
2. Resistance Temperature Detector (RTD)
The SureFire BMS-300 System uses an RTD to monitor temperature and control the SureFire System. It
is a 3-wire RTD with a 9” Insertion Length and 1/2” NPT Threads. The RTD Circuit’s temperature range
is from 0oF/-18oC-530oF/276oC.
NOTE: Operational Temperature range of the BMS-300 System
is 0oF/0°C to 405oF/276°C.
System may be controlled manually using an external switch if this
function is desired.
To monitor temperature remotely via 4-20mA proper scaling is:
4 mA = 0oF/0°C
20 mA = 529o F/276°C
See Installation Guide
3. Low Watt Explosion Proof Solenoid Valve
The SureFire BMS-300 System is available in kit form with an ultra low watt explosion proof solenoid
valve to operate the main burner fuel valve, or pilot valve. It is a 3 way valve wit either 1/4” NPT or 1/8”
NPT. Exhaust port is fitted with a dauber screen standard.
BEST PRACTICE : SureFire recommends use of these solenoids for safe, SureFire control of all fuel
valves on site.
NOTE: COMPONENT SUBSTITUTION MAY RESULT IN UNSAFE CONDITIONS, DAMAGE TO
AND / OR VOIDING OF SUREFIRE PRODUCT WARRANTY.
See Installation Guide
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Component Description
4. Pressure Switch
Our pressure switch is a High Quality, Class 1 Div 2 unit that can be used to indicate various standbys
or shutdowns.
Uses and Features of the supplied Pressure Switch are:
1. Can work either normally open or normally closed.
2. It can be used to sense loss of fuel gas.
3. Can be used to sense if gas is being vented.
4. It can be installed in series on either the shutdown or the
standby interlocks.
5. Can be used as primary control input when installed in
line with a temperature control T12. *Consult tech
support for this non standard implementation.
BEST PRACTICE: Install the pressure switch to function as
a Proof of Fuel Gas Standby sensor.
 Install the pressure switch above the fuel pot on the fuel
supply, and upstream from all control solenoids
 Connect wires to a standby interlock on the SureFire controller. When the gas pressure is lost, unit
will go into a standby mode. When gas pressure returns, the unit will automatically return to normal
operation.
 This method is especially helpful as it can mitigate unauthorized modification of your T-12 high limit
setting, and will provide a remote signal when unit goes offline as a result.
 THIS IS THE RECOMMENDED SUREFIRE INSTALLATION METHOD. If the recommended
method is not used, and incorrect T-12 adjustment can result in unit shutdown requiring manual
reset. This can occur when someone resets the T-12 incorrectly. This can create an especially
difficult issue to solve without the pressure switch in lone and acting on a standby to provide a
tattletale.
5. Slow Flow Valve
Our 1/4” slow flow valve is installed for use on all single or 2 stage applications. The slow flow is normally installed on the downstream side of the solenoid before it goes into the main burner fuel motor valve.
NOTE 1 : Some site specific fine tuning of slow flow valve
actuation for the main fuel valve timing may be necessary
onsite. See Slow Flow valve installation notes.
BEST PRACTICE: A Slow Flow Valve is BEST PRACTICE on
every FT-2—FT-6 system.
BEST PRACTICE: This valve is BEST PRACTICE in
conjunction with all large motor valves on single stage
systems.
See Installation Guide
NOTE: Please request the slow flow valve installation manual
and videos from SureFire Burner Management Systems
ENM-613-004
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Component Description
SureFire BMS-300 Options
6. AC to DC Power Supply and UPS
(Un-interrupted Power Supply)
SureFire offers a purpose designed power supply to be used to power the SureFire system where 120
VAC is available on site. The SITE maintains the battery and automatically switches to the battery when
a loss of AC power occurs. The power supply comes mounted in a separate enclosure and prewired.
See Installation Guide
7. Base SureFire Sparkless Igniter
The SureFire sparkless igniter is purpose built for the ignition of natural gas in the harsh environment of
the oil and gas industry. It comes standard with high temperature, and lead wires.
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OPERATION & SETUP
I.
Setting Up Process Temperatures
A.
To set the High Temperature on the SureFire BMS-300, follow these steps;
1. Press the high temp button to see what the current high temperature is
2. Unlock the system by pressing the hours on and up arrow for 4
seconds
3. Press and hold the high temp button and the use the up or down
arrows to adjust the temperature to your desired setting.
NOTE: High temp factory setting is 150°F/65.5°C
B.
To set the Low Temperature on the SureFire BMS-300, follow these steps;
1. Press the low temp button to see what the current low temperature setting is
2. Unlock the system by pressing the hours on and the up arrow for
4 seconds
3. Press and hold the low temp button the up or down arrows to
adjust the temperatures to your desired setting.
NOTE: Low temperature factory setting is 60°F/15.5°C
NOTE: Press and hold up or down arrow for 3 seconds to scroll
NOTE:
The SureFire System comes standard with a built in minimum
4° Fahrenheit Temperature Span to prevent undue wear
associated with equipment short cycling.
NOTE: While changing temperature settings, continue to hold
down on the TEMP button (high or low) and the up or down arrow,
and displayed value will begin to scroll at a faster rate.
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OPERATION & SETUP
II.
Setting Up the Flame Sensor Type
A. To set the flame rod as the flame sensor, follow these steps:
1. Unlock the system by pressing the hours on and the up arrow for 4 seconds
2. Press and hold the CAD/FR button and press the up or down arrow until FL is displayed
Note: Flame Rod is the factory default flame sensor type
III. Setting Up the Flame Sensor Threshold (FST)
The Flame rod threshold should be set at 250.
Unlock the system by pressing the hours on and the up arrow for 4 second
To change your flame rod threshold push the FTS button and up or down to adjust the value.
NOTE: Flame rod is the default setting on the BMS-300, and is programmed to work with the FTignition units without adjustment. NO USER ADJUSTMENT OF THE FST IS NECESSARY
IMPORTANT: Optimum FST is set at the factory. Making adjustment to this setting can result in
unstable operation, only authorized technicians should attempt this adjustment
BEST PRACTICE: Ensure continuity between the earth ground screw on the circuit board (far right,
lower screw on the circuit board) to the chassis ground
ABOUT FLAME RECTIFICATION: A flame rod functions by sensing a current passing through ions
in the flame, this phenomena is called Flame Rectification. The flame strength has a value that
ranges from 3-504. With flame rod technology , flame sensing is instantaneous, and completely independent of ambient light or temperature conditions. These benefits offer enhanced equipment
safety. A good flame will have a flame strength value from 3-5. The factory setting for the threshold
(FST) is 250 and should be left at that setting for flame rod use. Flame = a lower value, no flame = a
higher value. Flame rod sensing will have either a very high number like 504when there is no flame
or a very low number like 4 when there is a flame. The FT-1 when properly installed, can eliminate
these most common troubleshooting issues.
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OPERATION & SETUP
IV. Flame Strength
The SureFire BMS-300 has a flame strength indicator, based on a value from the flame
sensor.
To check flame strength:


Press the flame strength button.
See value on LED display
NOTE: While the burner is off, the value should be between 500-504
While the flame is present, the value should be between 3-5
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OPERATION & SETUP
V. Setting Up the Sparkless Igniter Voltage
The SureFire BMS-300 comes factory preset for use with the FT-1 Ignition unit and will
typically not require setup.
However in some cases it may be necessary to adjust the igniter voltage. The voltage,
can be adjusted to increase the output voltage to the igniter by 1 volt, though it is not
typically necessary. The controller comes from the factory preset at 13 VDC which is
ample power unless the igniter is nearing the end of its service life.
To increase voltage to the igniter, unlock system by holding down the hours on and up
arrow for 4 seconds. Hold voltage can adversely affect igniter life.
BEST PRACTICE: Do not increase voltage to the igniter unless necessary, undue high
voltage can adversely effect the igniter.
VI. Setting Up the Input Signal Selection
The SureFire BMS-300 System can be controlled by either of two different input devices. The
system can use temperature to control the system via an RTD, or it can be set up to use a discrete input switch via the ALT SENSE input.
NOTE: An example of an Alt sense device could be a pressure wtich, or a dry contact from a
PLC/RTU device.
To change the setup from RTD to ALT SENSE, use the following steps:
1.
Unlock the system by pressing the hours on and the up arrow for 4 seconds
2.
Press the RTD/PS button and read what the display says. 0=RTD P=ALT
SENSE
3.
Press and hold the RTD / PS button and use the up or down arrows to change to
your desired setting.
NOTE: The Factory setting for Input Signal is RTD
VII. Power Supply Setup
The SureFire accepts rated voltages as described in the spec. No setup is required.
However, the system does have a built-in volt meter to tell what the battery volts are at
all times. To check the battery volts, press the battery volts button. This can be helpful in
troubleshooting, but will replace a battery load tester
WARNING : If the battery volts drop below 11 volts at any time, a shutdown will
occur on code 13
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OPERATION & SETUP
VIII. Reading Attempts and Successful Ignitions Ratio
The SureFire BMS-300 has a built in counter to count the number of ignition attempts
and successful ignitions (A/S). To utilize this troubleshooting tool
1. Press the A/S Button.
The numbers displayed are the successful ignitions and the ignitions attempts
When you press the A/S button again you show on the two numbers
The higher number is the attempts and the lower number will be the success
NOTE: The counter starts at 0000 and will roll over after 9999.
IX. Hours On
1. The SureFire BMS-300 will count the total hours that the flame has been present.
To check the total numbers the flame has been on, press and hold the hours on
button
NOTE: The counter starts at 0000 and will roll over after reaching 9999
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OPERATION & SETUP
X. Fahrenheit or Celsius Setup
The SureFire BMS-300 has the ability to display the temperature in either Fahrenheit or
Celsius.
To check or change the *F/*C setup follow these steps:
1. Press the °F/°C Button (F or a C will be displayed)
2. After the system has been unlocked, press the button again to change it from °F to
°C.
NOTE: The Factory setting is Fahrenheit and an F will appear on the display.
XI. Status Codes Setup and Viewing
To see what is happening with the SureFire BMS-300 system, press the status code button. There will
be a number displayed on the screen which corresponds to one of the status codes printed on the control face of the unit.
To view the last error code, press the status code button before resetting the unit
XII. Optional Modes
To change between modes, unlock the system, then press the status code button for 4 seconds and
press the up or down arrow switch between modes
1 = Intermittent Pilot Mode
Stage on and stage two fuel gas solenoids shut off together once high temperature is reached
For Example:
High Temperature Setting = 150°F
Low Temperature Setting = 100°F
@ 140°F—both stage one and stage two solenoids are open
@ 150°F—both stage one and stage two solenoids are closed
2 = Standing Pilot Mode
Once the high temperature is reached, the stage two solenoid closed, but stage one remains open until
low temperature is reached, then stage two re-opens. If temperature reaches 10 degrees above the high
temperature set point both stage one and two close. If the temperature continues to rise to 20 degrees
above the high temperature set point, the system sill shutdown on a code 18
For Example:
High Temperature Setting = 150°F
Low Temperature Setting = 100°F
@ 140°F—both stage one and stage two solenoids are open
@ 150°F—stage two closes, stage one remains open
@ 160°F—stage two remains closed, stage one closes
@ 170°F—Both stage one and stage two remain closed, and system is shutdown on code 18.
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Status Codes
Standby Codes: (Green Light Blinking) - indicating that a standby mode has been activated
Code:
02
03
04
Definition:
Standby Interlock Activated
Spare Standby 1Activated
Spare Standby 2 Activated
RUN CODES: (Green Light Solid)
Code:
00
01
06
07
08
09
Definition:
System Running
Waiting for Startup Signal
Igniter On
Verifying Flame
Purge Between Ignition Attempts
Waiting for Stage 2 Solenoid Valve to Open
Code:
SHUTDOWN CODES: (Red Light Solid)
Definition:
Manual/Remote Shut Off
11
SHUTDOWN CODES: (Red Light Blinking)
Definition:
Code:
12
13
14
15
16
17
18
19
20
21
22
ENM-613-004
Flame Failure (3 Unsuccessful Attempts)
Low Battery Volts/Power Loss (Below 11 volts)
SureFire Igniter Short Circuit
SureFire Igniter Open Circuit
Flame Sensor Short Circuit/Flame Sensed Before Startup
Not Used
Extreme High Temperature Shutdown or RTD Problem (20°F above high temp)
Shutdown Interlock Activated
ESD Activated
Main Fuel Valve Failure
Flame Detected Before Start Up
23
Initial Start Up
First-Time Startup Procedure using an FT-1
1.
2.
3.
4.
5.
6.
7.
8.
9.
Read Setup Section of the Operations Manual to verify proper setup of all values as needed.
Turn off all gas sources to the main and pilot before attempting to test the system.
Ensure area is free from explosive gas.
Check the burner arrestor and housing for proper sealing prior to turning the gas on.
Turn the pilot gas on and set it to 5 psig and keep the main burner gas valve turned off.
Ensure the High Limit T-12 (if used) is set to 20°F/-6°C above SureFire High Temp setting.
Turn power on to the SureFire unit by plugging in the battery or power supply.
Push the on button and if everything is setup correctly the Green light will illuminate.
If the Red light is blinking press the Status Code button and match the number with the code under
Shutdown Codes and correct the problem. See the Trouble Shooting Guide.
NOTE: RTD/display temperature must be below the low temperature setting for unit cycle on
BEST PRACTICE: During Troubleshooting and first startup— Temporarily set the low temperature
higher than the display temperature, and set the high temperature 10 degrees above the low. Finally, set
all temperatures to desired set points prior to initial startup
STARTUP NOTE: On initial startup of the system, it may require a few attempts to ignite. This is
normal, as it will take some time for the fuel lines to vent air and fill the fuel lines with combustible gas.
WHAT TO EXPECT DURING STARTUP :
1. When the audible alarm stops the amber light should illuminate indicating the sparkless igniter is
coming on.
2. After 5 seconds the Blue light should illuminate indicating the “Stage 1 / Pilot” solenoid has opened.
3. When the Pilot ignites, and the controller detects a flame, the amber LED will turn off.
4. The Green and Blue LED will remain on until the high temperature is reached or a fault occurs.
If a flame is not detected within 15 seconds the system will shut off all valves and then enter
into a 120 second purge to allow any excess gas to evacuate the fire tube before the next ignit
ion attempt. A total of three incomplete ignition attempts will be allowed before the system shuts
down and requires a manual or remote reset.
SETUP TIP: Demonstrate proper function of each section of the system:
1. To demonstrate proper flame sense and shutdown functions. Turn the pilot valve off and the system
will close the solenoid valves, enter into the 120 second purge cycle, and then attempt to ignite
2. To Demonstrate solenoid function. Turn the system off by pressing the OFF button, then open the
manual all valves for the pilot and main burner gas, no gas should be flowing into the burner at this
time
3. To demonstrate proper fuel/air mixture, Once the main burner comes on and stabilizes, confirm the
proper air/combustible gas mixture according to the flame color and sound; blue flame with yellow
tips s the best coloration and lame sound should be smooth. Adjust air/combustible gas mixture if
necessary to achieve best results
4. To demonstrate system’s process sequence. Reset the temperature set points to desired vessel
temperatures and allow the system to reach high temp setting, verifying burner shutoff. Allow unit to
cycle a few times.
BEST PRACTICE: To ensure quality results, SureFire requires a qualified burner technician
inspect and tune the burner upon completion of every SureFire installation, immediately after
making any changes, and after performing maintenance to the system or burner.
ENM-613-004
24
Low temp is
reached
Yes
No
If in Shutdown
mode, alarm signal
will be sent out
No
Wait for signals to
change
No
120 second count
down
System checks valve closure,
interlocks and ESD are OK at
all times
Yes
Yes
Waits for ON
button to be
pushed
Yes
Alarm
will
beep for
5 seconds
Yes
Igniter
comes on for
5 seconds
prior to stage
1 solenoid
valve coming on
No
Yes
Stage 1
solenoid
valve
comes
on
Yes
No
Igniter
remains on
for up to 15
seconds,
unless gas
igniters and
proves a
flame
Yes
No
Shuts off solenoid valve.
Waits for
120secondsand
stars at the
beginning
No
Shuts off solenoid valve.
Waits for
120secondsand
stars at the
beginning
No
Proves
flame for
2 seconds
Goes into soft
Standby mode
Flow Chart Using Sense to Start System
Igniter Failure
System goes
into Shutdown
Shuts off solenoid valve.
Waits for
120secondsand
stars at the
beginning
Yes
Yes
Waits for signal to
change from Alt
sense switch
Yes
Waits 60 seconds, Stage 2
solenoid valve
comes on
Yes
Yes
Yes
25
ENM-613-004
Low temp is
reached
Yes
No
If in Shutdown
mode, alarm signal
will be sent out
No
Wait for signals to
change
No
120 second count
down
System checks valve closure,
interlocks and ESD are OK at
all times
Yes
Yes
Waits for ON
button to be
pushed
Yes
Alarm
will
beep for
5 seconds
Yes
Igniter
comes on for
5 seconds
prior to stage
1 solenoid
valve coming on
No
Igniter Failure
Stage 1
solenoid
valve
comes
on
Yes
Igniter
remains on
for up to 15
seconds,
unless gas
igniters and
proves a
flame
Yes
No
Shuts off solenoid valve.
Waits for
120secondsand
stars at the
beginning
No
Shuts off solenoid valve.
Waits for
120secondsand
stars at the
beginning
No
Proves
flame for
2 seconds
Goes into
Standby mode
Flow Chart using RTD Control
Yes
No
System goes
into Shutdown
Shuts off solenoid valve.
Waits for
120secondsand
stars at the
beginning
Yes
Yes
Waits for high
temp signal
Yes
Waits 60 seconds, Stage 2
solenoid valve
comes on
Yes
Yes
Yes
26
ENM-613-004
Installation
WARNING:
The SureFire BMS-300 Burner
System is to be installed by
SureFire Certified Technicians.
Installation by uncertified
individuals may result in; unsafe
conditions, damage to the
SureFire and other equipment,
personal injury, voiding the
SureFire warranty
CAUTION:
Before attempting to operate or
modify settings on any SureFire
Burner Management System,
please read and understand all
related product publications in
their entirety.
ENM-613-004
27
INSTALLATION
Enclosure Installation
The SureFire BMS-300 housed in a Fiberglass Enclosure.
To mount the BMS-300
1.
2.
3.
4.
The enclosure is to be mounted on a pole or on a building that is capable of supporting 10 pounds
Position the enclosure so that the front display can be clearly seen by an operator
Conduit Seal-off fittings for all electrical connections at the box are strongly suggested
Installation must comply will local codes
Unistrut
Unistrut Clamp
Mounting Hardware
BEST PRACTICE : After completing your installation and confirming proper operation, lock or tag your
control unit box to prevent unwanted or unauthorized modifications.
BEST PRACTICE: Locate your control unit in such a way as to be clearly visible by the operator
NOTE: Before any welding is attempted, disconnect all wires going to circuit board
Any damage caused by welding to your SureFire is NOT covered under warranty
ENM-613-004
28
INSTALLATION
FT-1 SPARKLESS IGNITER Installation
The SureFire BMS-300 System uses a proprietary SureFire igniter housed within the FT-1 ignition unit.
The FT-1 and the enclosed igniter require no user adjustment.
1.
2.
3.
4.
Shut down the unit and turn off all fuel gas
Remove existing pilot nozzle and nipple, leaving fuel/air mixer and pilot fuel supply in place.
Install the FT-1 nozzle 1” behind the main burner nozzle
The igniter has two wires that are white in color. These wires are not polar sensitive and are capable
to handle high temperatures encountered in burner tubes. Run igniter wires to the SureFire
controller J1, blocks 31 and 32
5. The FT-1 has a single high temperature wire provided for the flame sensor. Run the flame sensor
wire to the SureFire controller (J5 block)
6. Verify continuity for all wiring prior to reinstalling burner into the fire tube.
FT-1 Nozzle
Igniter Fitting
and Leads
Flame Sensor
(Flame Rod)
NOTE: Earth grounding is a requirement when using a flame rod. Please check for proper grounding by
connecting a multi-meter between the nozzle and the grounding lug on the circuit board.
ENM-613-004
29
SureFire BMS-300 Operation Manual
INSTALLATION
RTD Installation
The SureFire BMS-300 can be temperature controlled using a supplied RTD (Resistance Temperature
Detector).
BEST PRACTICE :
 Install the RTD included in the kit into a appropriate temperature well on the vessel. If no dedicated
well exists, it is an accepted practice to remove the temperature controller (KimRay T12 or similar
device) utilized for temperature control.
Please ensure that the RTD is the proper size for your
available port
 Use plenty of heat transfer grease on the RTD stem for
good heat transfer.
 Some units may have two T12 temperature controllers
- one to control temperature and the other to shut off
the supply if the temperature exceeds a HIGH LIMIT
setting. It is acceptable to leave the second high limit
controller in place, the HIGH LIMIT setting of this T12
must be 20°F/11°C above the SureFire high temp set
point for proper operation.
NOTE: The RTD has three wires, two negative and one positive, wire color may vary. The identical color
wires are negative, the other wire is the positive. Improper RTD connection may result in unsafe or
improper operation.
ENM-613-004
30
SureFire BMS-300 Operation Manual
INSTALLATION
RTD 4-20mA Remote Temperature Integration
The SureFire BMS-300 can be temperature controlled using a supplied RTD (Resistance Temperature
Detector), this RTD circuit provides for remote monitoring using an industry standard 4-20mA loop powered circuit. This circuit must e powered from the customers device @ 12 to 30 VDC
BEST PRACTICE:
The proper connection method for the 4-20mA RTD remote circuit monitoring is as follows:
NOTE: Customer Supplied
1. Connect positive side of the power supply from the remote monitoring
equipment to the (J2 block) number 5 terminal (+ 4-20mA)
2. Connect a wire from (J2 block) number 4 (- 4-20mA) terminal to the remote
monitoring equipment
3. If a 1-5 V signal is desired instead of the 4-20m, please install a 250 Ω resistor
(at the remote monitoring equipment) to the return in the step 2 and connect the other
end of the resistor to the NEG side of the power supply. Monitor the VDC signal at the
250 Ω resistor (return wire)
NOTE: Scale accordingly: 4mA = 0°F/0°C
NOTE: Scale accordingly: 20mA = 529°F/ 276°C
WARNING
Deviation may produce undesired results
ENM-613-004
31
SureFire BMS-300 Operation Manual
INSTALLATION
Solenoid Valve Installation
The SureFire BMS-300 comes with 12 Volt Explosion Proof Solenoid Valves used to control instrument
gas and drive the opening and closing of the pilot and main burner valves.
Installation:
1. Ensure instrument gas is shut off
2. Locate the instrument gas supply line feeding the main burner valve
3. Cut the supply tubing, allowing enough room for the solenoid to be installed in close proximity to the
SureFire controller.
4. Use two 1/8” NPT x 3/8” tubing fitting
and connect the solenoid inline
1/8” NPT INLET
5. Trim the unused GREEN wire short
and cap off with a wire nut as this
1/2” NPT Conduit
wire will not be used
6. Use the proper conduit and connectors
and wire the solenoid to the SureFire
system.
INLET = Supply in
CYL
= Supply out to Motor Valve
Exhaust Vent
ASCO SOLENOID:
1. Ensure instrument gas is shut off
2. Locate the instrument gas supply line feeing the main burner valve
3. Cut the supply tubing, allowing enough room for the solenoid to be installed in close
proximity to the SureFire Controller
4. Use two 1/4” NPT x 3/8” tubing fittings and
connect the solenoid in-line
5. Trim the unused GREAN wire short and
cap it off with a wire nut as this will no be
used.
6. Use the proper conduit and connectors and
wire the solenoid to the SureFire system
1 = Outlet
2 = Inlet
ENM-613-004
32
INSTALLATION
Slow Flow Valve
A slow flow valve is used to restrict the gas going into the motor valve so the valve will open slow and
smooth. The purpose of the slow flow valve is to have the main burner motor valve begin opening slowly, but open completely within 2-3 seconds on single stage applications.
Installing the Slow Flow Valve:
Adjustment
Setscrew
1. Turn of the system
2. Shut off all fuel and instrument gas
3. Install the slow flow valve in the instrument gas line
located between the main fuel solenoid and the
main burner motor valve.
4. Cut into the tubing and install the slow flow valve
Inlet
with 1/4” NPT fittings
5. Locate the slow flow valve adjustment set screw
and loosen the locknut
6. Turn the locknut counter-clockwise until it reaches
the top of the adjustment set screw. Adjust the set
screw clockwise until resistance is felt. Then adjust
the setscrew counter-clockwise a 1/4 turn
7. Turn the system on and observe, the main burner
motor valve should slowly increase in velocity
8. When satisfactory timing is obtained, lock the setscrew locking nut and verify settings by cycling the
system.
Locking Nut
Outlet
Testing the Slow Flow Valve:
Turn the locknut counter-clockwise until it reaches the top adjustment set screw. Adjust the set screw
clockwise until finger tight. Run the system through a cycle. Once the blue Led illuminates, the motor
valve should not open, if it does, the slow flow valve needs cleaned
Cleaning the Slow Flow Valve:
Turn the slow flow valve until the cover plate is facing upward. Remove four screws, then carefully remove the cover plate, exposing the internals. Remove all dirt, dust, debris and trash from the internals.
Use compressed air to blow into the inlet port of the valve to remove all internal debris and trash. Place
internals back into the valve, and carefully screw the cover plate back on to the valve. Turn the slow flow
valve back to its upright position. Re-test the slow flow valve. Once blue LED illuminates, the motor
valve should not open, if it does, replace the slow flow valve.
Helpful Fine Tuning Hint:
If the burner comes on too fast, then adjust clockwise 1/8th of a turn and try again.
CLOCKWISE = SLOWER OPERATION
COUNTER-CLOCKWISE = FASTER OPERATION
Cycle the system several times to ensure the slow flow valve is set properly and it lights smoothly before
tightening the locknut.
NOTE: Please reference SureFire Slow Flow Valve Instructions
Contact SureFire for more information.
ENM-613-004
33
INSTALLATION
Slow Flow Valve
Cover Plate
Rubber Seat
Internals
Spring
Pressure Switch
The pressure switch is a high quality, Class 1 Div 2
unit that can be used to indicate various standbys or
shutdowns
Optional Pressure Switch Applications





Normally open or normally closed
Used to sense loss of fuel gas
Used to sense if gas is being vented
Installed on either the shutdown or the standby
interlocks
May be used as a primary control input when installed
in–line with a temperature control T12. Consult with
tech support for this is a non standard implementation
Installation of the Pressure Switch:


Install pressure switch downstream of the high limit T12, and upstream from all the solenoids.
Connect wires to a standby interlock on the SureFire controller. When gas pressure is lost, the unit
will go into a standby. When gas pressure returns, the unit will automatically go back to normal
operation.
 THIS IS THE RECOMMENDED SUREFIRE INSTALLATION METHOD
If the recommended method is not used, an incorrect T12 setting can result in unit shutdown requiring a
manual reset. This can occur when unauthorized personnel resets the T12 incorrectly
ENM-613-004
34
BASIC INSTALLATION
OPTIONAL: Actuator Valve Installation
BEST PRACTICE:
SureFire recommends using a Bettis Actuator valve
Model # EM 300M-C7-10-001-PM
If used, an actuator valve MUST BE ADJUSTED AND SET UP WITH PROPER SUREFIRE TIMING to
function with the SureFire safety programming protocol. Valve timing must begin to open in 2-3 seconds.
Adjust the Actuator if necessary to achieve this timing.
The SureFire has a built-in DPDT relay for proper operation of many actuators requiring three wires.
Desired valve must be useable with the SureFire DPDT.
IF USING A ACTUATOR VALVE OTHER THAN THE BETTIS AS DESCIRBED, PLEASE CONSULT
WITH THEMANUFACTURES INSTALLATION LITERATURE.
Wiring the Actuator Valve:
On the Bettis actuator circuit board, there is a connector strip, 1,2 and 3 connectors of the actuator will
be wired to the corresponding 1,2 and 3 actuator ports on the SureFire circuit board.
Install the actuator valve into the main fuel line just prior to the line entering into the burner housing as
per the actuator manufacture's specification
To Burner
Conduit Connection
FLOW
ENM-613-004
35
INSTALLATION
Power Options
1. 12 VDC battery and solar panel
2. 120 VAC to 12 VDC converter
3. 24 VDC to 12 VDC converter
This SureFire BMS-300 can use either an appropriately specified AC to 12 VDC converter or a properly
sized 12 VDC batter and solar panel as a power supply or an optional DC to DC converter that provides
sufficient amperage.
NOTE: The circuit board is rated for 12 VDC,
WARNING: DO NO CONNECT A 24 POWER SUPPLY DIRECTLY TO THE CIRCUIT
BOARD
CAUTION: ENSURE PROPER POLARITY BEFORE APPLYING POWER TO
SUREFIRE UNIT.
BEST PRACTICE: Solar and battery sizing are extremely dependent on the local conditions, please
consult your solar power provider for information suitable to your location.
ENM-613-004
36
Notices
NOTICE:
ADHERANCE TO THE CODE:
Install all wiring in the appropriate conduit and use seal-offs where they are required. Adhere
to all other code installation requirements
CAUTION:
Label all wires prior to disconnection when servicing the controls. Wiring errors will cause
improper and dangerous operation.
ATTENTION:
Étiqueter tous les fils avant de les débrancher lors de l'entretien des contrôles. Les erreurs de
câblage causeront fonctionnement incorrect et dangereux.
NOTE: Determine all applicable local electrical requirements before installing the system
BEST PRACTICES
1. Use wire nuts when connecting device wire to field installed wire
2. Ensure Proper wire gauge to all components
3. After connecting wire to the terminal blocks, tug slightly on them to ensure they are secure
4. When stripping the wires to install in the terminal block, ensure that the wires have no way
of making connection or grounding to other wires
5. Ensure that you clamp down on the bare wire and not the insulation to ensure that the
wire will make proper connection
6. Run the wire into the enclosure, open the door and cut the wires as short as possible,
leaving enough wire to still be able to open the door 180 degrees.
7. Use small wire ties to keep your wires neat inside of the enclosure
8. When you close the door make sure that no wires are being pinched or have come loose
ENM-613-004
37
BMS-300 WIRING DIAGRAM
ENM-613-004
DRAWINGS
38
Pilotless Fuel Train
ENM-613-004
DRAWINGS
39
Piloted Fuel Train
ENM-613-004
DRAWINGS
40
INPUTS AND OUTPUTS 1
INPUT and OUTPUT GRID #1
TERMINAL
BLOCK
EXTERNAL DEVICE
SYSTEM FUNCTION / STATE
NOTES
J5 Block
Terminal 1
CAD EYE
Active
Terminal 2
Not Used
Inactive
Terminal 3
FLAME ROD
Active
Terminal 4
Not Used
Inactive
Terminal 5
Not Used
Inactive
Terminal 6
CAD EYE
Active
MUST
HAVE
QUALITY
GROUND
J6 Block
Emergency Shutdown Sole-
ALT Solenoid noid Valve / Double Block and
Terminals 1 & 2
Stage 2 Solenoid
Terminals 3 & 4
Bleed Solenoid Valve
Main Solenoid Valve
Normally Closed
Relay
12 VDC
supplied by
SureFire
12 VDC
Normally Open Relay supplied by
SureFire
Vertical Terminal Blocks
J2 Block
Actuator Valve
Terminals 1, 2 & 3
Actuator Valve
DPDT Relay
Provided on SureFire
See your
Actuator
install
Manual
System RTD signal
PLC/RTU must
be calibrated,
see page 32 for
more details
4 - 20 mA OUT End User PLC or RTU supplies pass through enables
Terminals 4 & 5
voltage to SureFire system
remote temperature
monitoring
Alarm / Run End user PLC/RTU supplies Run Status = closed
Status voltage to SureFire system Alarm Status = Open
Terminals 6 & 7
System State
Run Status / Alarm State
Open
Closed
Off
Error
Loss of Power
Standby
Open
Open
Open
Open
ENM-613-004
NOTES
On Reset,
safety purge
cycle will
count down
prior to status change
41
INPUTS AND OUTPUTS 2
INPUT and OUTPUT GRID #2
TERMINAL BLOCK
EXTERNAL DEVICE
SYSTEM FUNCTION /
STATE
NOTES
Vertical Terminal Blocks
J2 Block
Stage 1 Solenoid Pilot Burner Solenoid
RTD
Terminals 10, 11 & 12
Remote On
Terminals 13 & 14
Remote Off
Terminals 15 & 16
Standby Interlock
Terminals 17 & 18
SureFire RTD
Sensor
Normally Open Relay
Port is Active unless
system is programmed
to operate in
“P” (Alt Sense) Mode
DRY CONTACT CLOSED
REMOTE ACTIVATION
DRY CONTACT CLOSED
REMOTE DEACTIVATION
DRY CONTACT OPEN
STANDBY
DRY CONTACT OPEN
SHUTDOWN
DRY CONTACT OPEN
SHUTDOWN
DRY CONTACT OPEN
STANDBY
J1 Block
ESD
Terminals 19 & 20
Proof of Value Closure
Shutdown
Terminals 21 & 22
Spare Standby 1
Terminals 23 & 24
Shutdown Interlock DRY CONTACT Terminals 25 & 26
Spare Standby 2
Terminals 27 & 28
OPEN
DRY CONTACT OPEN
SHUTDOWN
STANDBY
12 VDC supplied by SureFire
RTD is
polarity
sensitive,
balanced.
MOMENTARY
Remote on / off integration
SWITCH
may be combined on one
PROVIDED
DPDT switch for
BY END USsimplicity.
ER.
MOMENTARY
SWITCH
PROVIDED
BY END USER.
NOTE:
If ANY
Standby is
activated,
Unit will not
resume
process until
standby
signal is
de-activated.
*Standby does
not require
reset.
SWITCH PROVIDED BY END USER.
SWITCH PROVIDED BY END USER.
SWITCH PROVIDED BY END USER.
SWITCH PROVIDED BY END USER.
NOTE:
If ANY Shut
Down is
activated,
Unit will
require
manual or
remote reset
in order to
resume
process.
SWITCH PROVIDED BY END USER.
SWITCH PROVIDED BY END USER.
NOTE: ANY STANDBY OR SHUTDOWN MUST BE JUMPERED IF NOT IN USE.
UNSATISFACTORY OPERATION WILL RESULT WITHOUT JUMPER.
ENM-613-004
42
INPUTS AND OUTPUTS 3
INPUT and OUTPUT GRID #3
TERMINAL BLOCK
EXTERNAL DEVICE
SYSTEM FUNCTION /
STATE
NOTES
Vertical Terminal Blocks
Alt Sense Input
Terminals 29 & 30
SUREFIRE
IGNITER
Solar Panel/
24VDC Input
Terminals 33 &34
12V BATTERY
Terminals 35 & 36
To Reset a SureFire
System
ENM-613-004
DRY CONTACT
CLOSED/OPEN
BEGIN IGNITION /
STOPS BURN
SureFire Sparkless Igniter
DOES NOT FUNCTION WITH RTD
Non Polarity Sensitive
12 VOLT DC Solar Panel
ONLY
Solar Regulator
BATTERY OR SUITABLE
12VDC POWER SUPPLY
12 VOLT, DC ONLY
Polarity
Sensitive
NOT SUITABLE FOR
ANY 24 VOLT POWER
SUPPLY
Polarity Sensitive
Push the OFF button, push the ON button
43
Troubleshooting Guide
SYMPTOM
ACTION
System comes on and the igniter glows, but the 
gas does not ignite.





Verify correct gas pressure. (5-14 PSI)
After install or service, purge air from the fuel
line by cycling the ignition process a few times
Adjust the air/fuel mixer, start with less air and
work your way up. Restart to ensure correct
setting and lockdown the air valve
Test battery or power supply with an appropriate load tester. Replace if necessary.
Test for igniter wear. Disconnect igniter from
the system and use a multi-meter to test the
igniter Ω. Replace igniter if it reads >4Ω
Verify igniter alignment, ensure the element is
correctly positioned within the gas stream. This
step is not required with any FT units
The gas ignites, but does not stay on
Flame Sensor is not Sensing Flame
 Check the “FST” values and the CAD/FR to
make sure they are set right.
 Verify correct Flame Sensor position.
 The Slow Flow valve or Actuator valve is not
timed correctly, and is not opening quickly
enough.
 Adjust Slow Flow to correct timing per setup.
The high and low temp setup will not allow the
operator to set the high and low closer than
10°. ELITE series only, up to version 2.8
This is not an error SureFire systems are designed with a 10 degree minimum Low to High
Temperature span to help minimize short cycling
The temperatures will not go any higher or low- System is Locked
er when pushing the arrow keys.
 Unlock System to enable adjustment.
 System will not allow you to get closer than
10°.
 System has operation limits of 0°F and 405°F.
The system will allow the operator to view the
settings, but will not allow changes to be made
System is Locked
 In order to unlock the system, press the “hours
on” and the up arrow for 5 seconds
 Display will show 0000
 System is unlocked
 System will auto-lock after 5 minutes of no
button activity.
The Amber and Red LED is blinking and the
system will not start up
Igniter or Igniter Wiring Issue
 Press “status code” and observe display, a 14
or 15 indicates a open or short circuit
 Check wires for continuity. Check batter volts
 Check and resolve loose, grounded or damaged wires
 Replace igniter
ENM-613-004
44
Troubleshooting Guide
SYMPTOM
ACTION
The red LED is blinking and system will not
start up.
Shutdown is Activated
 Verify Status Code. Resolve Shutdown Device.
 Reset System by cycling OFF / ON button or
remote switch (if applicable).
Red LED is on, but not blinking.
Manual or remote System shut-off
 If desired, ON button will activate system.
The system is counting down from 120.
120 second safety purge between cycles.
 Burner did not ignite, will auto-retry after purge.
 Loss of flame
The green LED is blinking and the system will
not start up.
Standby is Activated
 System will not operate burner until standby
signal is resolved.
 Verify standby Status Code
 Troubleshoot standby devices
 When the standby is resolved, system will automatically resume function.
Status Code = 12
Flame Failure:
 Ignition has failed three consecutive times.
 Reset System
 Troubleshoot Fuel, Air, fuel pressure, Igniter
Status Code = 13
Low battery volts:
 The battery has dropped below minimum.
 Test the battery and replace as necessary.
Status Code = 14
Igniter Short Circuit :
 Check wiring for damage or other issues and
resolve.
 Igniter wires are touching each other
 Igniter wires are grounding on the conduit
Status Code = 15
Igniter Open Circuit :
 Igniter element is worn out or damaged.
 A wire has become disconnected.
 Likely battery failure, replace battery.
Status Code = 16
Improper Flame Detection— FLAME ROD:







ENM-613-004
Flame Rod is sensing a flame before start up.
Check for a leaking fuel valve.
Repair fuel valve.
Flame Rod Wire is improperly grounded
Flame Rod Wire is shorting.
Flame Rod itself is touching metal.
Flame Rod Sensor failure—Replace Flame
Rod.
45
Troubleshooting Guide
SYMPTOM
ACTION
Status Code = 17
NO LONGER USED
 Disregard Overlay
Status Code = 18
RTD Failure or Extreme High Temperature
Shutdown.




Verify RTD wiring
Test RTD for Failure
If RTD has failed replace RTD and reset system.
Process temperature has exceeded 20°F
above high temp set point.
Status Code = 21
Main Fuel Valve Failure:
 The switch on the main fuel valve is activated
and the valve may need to be repaired.
 The wires have become disconnected.
 If there is no switch on the fuel valve a Jumper
needs to be installed.
Status Code = 22
Improper Flame Detection— CAD EYE





Status Code = 02, 03, 04, 19, 20 or 21
If these functions are not being utilized.

ENM-613-004
SureFire is sensing a flame before start up.
Check for a leaking fuel valve.
Repair fuel valve.
Flame Sensor wiring short or damage.
Flame Sensor Failure—replace Cad Eye
When noted functions are not utilized they
must be jumpered.
46
Troubleshooting Guide
Test or Replace SureFire Fuse
1.
2.
3.
4.
Ensure power is disconnected and the area is non hazardous
Fuses are located in designations, F-1, F-2 and F-3. Please see fuse table for fuse identification.
Use continuity tester/voltmeter to test if fuse has been damaged or broken.
Place lead pins of testing equipment on the exposed pins on the fuse. If the fuse has no continuity,
the fuse has been damaged or blown
5. If the fuse is blown, safely remove and replace with a 12 volt, 5 amp, mini blade fuse (ATM-5)
ENM-613-004
47
SPECIFICATIONS
POWER SUPPLY REQUIREMENTS
Battery Volts
12 VDC
Solar Panel Volts
12 VDC
Daily Load
2.24-5.40 Amp Hours/Day
VOLTAGES
11-15 VDC
Solar Panel
12-20 VDC
Sparkless Igniter
13-14 VDC, Adjustable
4-20 mA
12-30 VDC
Solar Panel Current
2 Amp Max
IGNITION UNIT
Sparkless Igniter Load @ 13 Volts Out
4.25 Ω
Sparkless Igniter Load @ 14 Volts Out
4.50 Ω
NOM Good Igniter Ω Range
Igniter Current Draw
Less than 4Ω as measured DC Igniter from Controller
7 Amps inrush, 1.5 Amps NOM (during normal operation)
SENSOR
RTD Range
93.0 to 199.91Ω
ALT Sense Switch
Dry Contact Switch
Standby or Shutdown Inputs
Dry Contact Switch
Remote On/Off
Dry Contact Switch
RELAYS
Stage 1 Solenoid Load
3 Amps
Stage 2 and ALT Solenoid Load
3 Amps
Actuator Valve Load
3 Amps
OTHER
Blade Fuses
5 Amps
FLAME SENSOR
Gains
1, 10
Loads
5v, 1M Ω ( always)
5v, 10K Ω
12v, 10M Ω
Full Scale After Gain
ENM-613-004
0-5 Volts
48
UNLOCKING THE SUREFIRE BMS-300:
PRESS THE HOURS ON BUTTON AND THE UP
ARROW BUTTON AT THE SAME TIME AND HOLD
FOR 3 SECONDS.
0000 WILL FLASH ON THE DISPLAY FOR ONE
SECOND.
THIS LETS YOU KNOW THE SYSTEM IS UNLOCKED AND THAT CHANGES CAN BE MADE.
ENM-613-004
49
PROPRIETARY INFORMATION
Information disclosed herein contains
proprietary rights of SureFire Burner Management
Systems, LLC.
Neither this document nor the information
disclosed herein shall be reproduced or transferred
to other documents, or used or disclosed to others
for manufacturing purposes, or for any other
purpose except as specifically authorized in writing
by SureFire Burner Management Systems, LLC.
ENM-613-004
50
TWO YEAR WARRANTY
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 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.
ENM-613-004
51
INSTALLATION AND SETUP NOTES
Commissioning Date:
____________________________
Commissioning Value:
____________________________
High Temp:
____________________________
Low Temp:
____________________________
Status Code:
____________________________
FST:
____________________________
Igniter Volts:
____________________________
Hours:
____________________________
CAD/FR:
____________________________
RTD/PS:
____________________________
Battery Volts:
____________________________
Flame Strength:
____________________________
Other 1:
____________________________
Other 2:
____________________________
ENM-613-004
52
INSTALLATION AND SETUP NOTES
ENM-613-004
53
Burner management isn’t
just “something” we do,
it’s ALL we do.
www.surefire-controls.com
MADE IN U.S.A.
ENM-613-004
54