Proudly Made in the USA · BMS‐350 DESCRIPTION BMS-350 Circuit Board The SureFire BMS-350 system...

Proudly Made in the USA

BMS-350

Installation and

Operations Manual

2

BMS-350

The BMS-350 is designed for heavy-duty oil field applications, and possesses Class 1 Division 2 certification standards. The BMS-350 is designed to operate utilizing the SureFire FT ignition series to operate and monitor process equipment, flare, and combustor application .

The controller’s display is designed to operate in ambient temperatures from – 40° F to 131° F, and is coated for corrosion resistance. The unit is mounted in a NEMA 4X enclosure and supplied with a UV resistant key-pad. Each unit includes function indicator LEDs, and a status code chart to provide assistance in troubleshoot-ing situations. The unit requires 12V DC power, and is solar ready with a specific solar power termination port.

The BMS-350 monitors the target temperatures with either an RTD or Thermocouple, which indicates temper-atures (RTD) 0°F to 670°F or (Thermocouple) 32° F to 2700° F. The BMS-350 controls both the pilot and main burner gas valves as required, and is designed as a fail safe system. The system also contains high tem-perature shutdown, flame failure shutdown, along with a an audible startup warning. The system’s fail safe run status / alarm out functions allow for remote monitoring for environmental and regulatory compliance. Stand-ard remote feature include temperature indication utilizing an RTU or PLC, and Modbus read/write communi-cation through both RS-485 or RS-232.

The BMS-300 process may also be controlled using the alt sense input. Multiple connections for additional

standby and shutdown requirements are also provided.

Every SureFire system must pass complete factory QA/QC inspections before shipment.

Also available are control solenoid valves, resistance temperature detector (RTD), Thermocouple (T/C), flame sensor, fuel loss standby switch and FT ignition series.

We are dedicated to providing quality American made safety control systems for industrial burners. The BMS system has been developed through thousands of hours of critical design, engineering, and field testing.

INTRODUCTION

3

Certifications and Warnings 4

Warranty Statement 5

BMS-350 Description

Enclosure 6

Circuit Board 7

LED Indicators 8

Graphic Overlay 8

Keypad Functions 9

Component Descriptions

SureFire Ignition Units 10-11

Additional Components 12-13

Installation Guide 14-17

Installation Wiring Diagram 18

Fuel Train Diagrams 19

Controller Setup 20-25

Operation Guide 26-27

Operation / Flow Chart: Piloted and Pilotless System 28-33

Specifications 34

Troubleshooting Guide 35-40

Modbus Information 41-54

Software Versions 55

Contact Information and Manual Version 56

TABLEOFCONTENTS

4

CERTIFICATIONSANDWARNINGS

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 HAMILIN RE-LAY, MODEL HE721A0500

AVERTISSEMENT - L'exposition à certains produits chimiques peut dégrader les ETANCHEITE

Propriétés des matériaux utilisés dans les dispositifs suivants: RELAIS PANASONIC MODÈLE JW2SN-DC12V, ET RELAIS HAMILIN, MODÈLE HE721A0500

7.8 amps @ 12.0 VDC MAX

0.025 amps @ 12.0 VDC AVG

ETL Certified to the Following Standards:

Certified To:

CSA STD C22.2 No. 61010 -1

CSA STD C22.2 #213

Conforms To:

UL STD 61010 –1

ISA STD 12.12.01

5

WARRANTYSTATEMENT

Warranty Statement

SureFire warrants all equipment of its own manufacture to be free of defects in material and

workmanship for a period of twenty-four (24) months from the date of manufacture. SureFire’s

sole obligation hereunder shall be expressly limited to repair or exchange free of charge, F.O.B.

Farmington, NM, USA of such defective equipment. SureFire’s obligation under this warranty is

limited to the above and does not apply to claims which are a result of improper installation, mis-

use, 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 oth-

er 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 other-

wise, including any implied warranties or conditions of merchantability, quality or fitness are here-

by excluded and, SureFire shall not be liable for any loss, cost or damages, of any kind whatsoev-

er, 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 lia-

bility shall continue to be enforceable between the parties notwithstanding termination of the with-

in 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.

6

BMS‐350DESCRIPTION

Enclosure The SureFire BMS-350 system uses a polycarbonate NEMA 4X Enclosure to house the circuit board. The Graphic overlay with a membrane keypad is mounted on the exterior of the enclosure.

The NEMA 4X enclosure provides a high level of protection from harsh outdoor elements:

Windblown Dust Protection

Water Damage Protection - Rain, Sleet, Snow, Splashing and Direct Water Contact

Corrosion Protection

External Formation of Ice Protection

The Enclosure is IP66 certified, meaning it has been tested to the following:

Dust tight, no ingress of dust; complete protection against contact

Water projected in powerful water jets (12.5mm nozzle) against the enclosure from any direction shall have no harmful effects.

WARNING:

When drilling holes in the enclosure, ensure IP66 fittings are used to maintain the IP66 standard. Failure to use IP66 standard fittings nullifies the IP66 certification.

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BMS-350 Circuit Board

The SureFire BMS-350 system is controlled by a state of the art, non-arcing electronics that monitor and control all burner functions. It comes with 4 LED indictors and a status code LED display. It contains in-dividual spring loaded terminal blocks for ease of wiring termination and installation.

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Graphic Overlay The overlay has commonly used status codes printed on the face. The overlay is used for interfacing with the program and setting up the unit.

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

Blinking - Indicates a standby interlock is activated

RED LED ON - Indicates that the system is off

Blinking - Indicates a shutdown failure or interlock has been activated

AMBER LED ON - Indicates the igniter is on

Blinking - Indicates an igniter failure

BLUE LED ON - Indicates that a flame has been sensed

GREEN

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

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Keypad Functions

The SureFire BMS-350 has a 16 button keypad to assist in controlling and monitoring the system.

Button Functions

Up Arrow Increases the current value Press & hold for 5 seconds to unlock the system - A series of zeros will appear on the display screen

Down Arrow Decreases the current value

Press & hold for 5 seconds to re-lock system.

High Temp Displays High Temperature setting

Locked Mode - Press & hold for 5 seconds to display the Safety Thermocouple’s current temperature

Low Temp Displays Low Temperature setting

Flame Sense Displays current flame sensing device

F - Flame Rod H - Thermocouple

Temp Control Displays current controlling device

A - Alt Sense 1 - RTD 2 - Thermocouple

Status Code Displays code that corresponds with the current unit status

Press & hold, use the up & down arrows to display the past 9 codes

EHTD Displays current Extreme High Temp Delta setting

Battery Volts

Pilot Mode 1/2 Displays current pilot mode

1 - Intermittent Pilot 2 - Standing Pilot

FPT Displays current Flame Proof Timing setting

Solenoid Timing Displays current timing between stage 1 & stage 2 opening

Flame Strength Displays current flame strength for the Flame Rod or Thermocouple

Press & hold for 5 seconds to display the Safety Thermocouple shutdown setting

AUX

Displays current igniter Ohms

Press & hold, use the up & down arrow button to display: System days On, Burner Days On, Ignition Attempts & Successful Ignitions.

OFF Turns system OFF

ON Turns system ON

Displays current voltage being supplied to the unit.

Primary

Secondary

Primary

Secondary

Primary

Secondary

Primary

Secondary

Primary

Secondary

Primary

Secondary

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COMPONENTDESCRIPTION

SureFire FT-Series Ignition Units The SureFire BMS-350 is compatible with most FT series

igniters. Each unit is designed for specific applications.

Piloted System

FT-1 System are designed for long life in burner

applications as a pilot. The FT-1 series offers

flame sensing through flame rod or thermocouple.

NOTE: Please consult local SureFire Field Tech Support

for proper pilot placement and proper orifice sizing selec-

tion.

FT-1-SF (above)

These unit above is utilizing a Flame Rod as a flame sensing mechanism.

Optional Flame Sensors Flame Rod Nichrome flame rod rated to 2600°F Armored wiring harness rated to 1000°F duty / 1500°F

flash Enclosed fire tube service Direct termination to BMS-350 controller Thermocouple

Type K thermocouple flame sensing rated to 2400°F

Armored wiring harness rated to 1000°F duty / 1500°F flash

Exposed combustor or incinerator service

Direct termination to the BMS-350 controller

FT-1-ST (above)

These unit above is utilizing a Thermocouple as a flame sensing mechanism.

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COMPONENTDESCRIPTION

Pilotless Systems

The pilotless systems offer ease of installation for a

range of applications. Each of these units are available

with flame rod or thermocouple flame sensing.

FT-2 Systems are suitable for pilotless 1” burner

applications, rated at 125,000 btu/H


applications, rated at 500,000 btu/H


applications, rated at 1,000,000 btu/H

NOTE: Please consult local SureFire Field Tech

Support for proper pilot placement and proper ori-

fice sizing selection.

FT-2-AF:

This unit above is utilizing a Flame Rod as a flame sensing mechanism.

FT-4-AF (above) and FT-6-AF (below): These two unit are utilizing a

Flame Rod as a flame sensing mechanism.

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COMPONENTDESCRIPTIONS

1in. & 2in. SureFire Solenoid Valve

The 1in. SureFire solenoid valve is a fail closed device, meaning if power is lost, the unit defaults to a closed state

No adjustment necessary! Simple 2 wire termination Kalrez elastomer plunger. Plunger replacement kits available. Applications include - pilotless operation, non-venting fuel

trains, and flares

12 Volt SureFire Actuator

The 12V SureFire actuator is designed to control the main fuel gas to the main burner

No adjustment necessary! The actuator is factory pro-grammed and pre-wired

1” NPT X 1” NPT connection, full port

Simple 3 wire termination

Proof of valve closure kits available

Applications include - pilotless operations , non-venting fuel trains, and flare systems

1/4 in. ASCO Solenoid Valve

The 1/4 in ASCO solenoid valve is a fail closed device, meaning if power is lost, the unit defaults to a closed state.

No adjustment necessary! Simple 2 wire termination.

1/4” NPT X 1/4” NPT connection

Applications include– direct pilot control valve (#70 ori-fice) and pneumatic valve operation.

Please Contact SureFire for appropriate product part number.

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COMPONENTDESCRIPTIONS

Pressure Switch

Used on a variety of standbys and shutdowns Can be set as normally open or normally closed. Adjustable from 1 psi — 15 psi. 316 SS construction, wetted parts are NACE

Resistance Temperature Detector

Used to detect the process temperature. Temperature range is 0°F — 670°F. Simple three wire termination. 1/2” NPT X 1/2” NPT connection Available in the following sizes: 5”, 6”, 9”, 12”, and 18”.

Slow Flow Valve

Reduces the inrush of fuel gas into the diaphragm valve for smooth and reliable ignition.

Required on all pilotless installations when not using an actuator valve.

1/4” NPT X 1/4” NPT connection Recommended for piloted installations to assure optimum

performance and reliability.

Thermocouple

Type K thermocouple used to detect the process tempera-ture.

Temperature range is 32°F — 2400°F. Simple two wire termination. 1/2” NPTX 1/2” NPT connection Available in the following sizes: 6” and 9”.



14

INSTALLATIONGUIDE

Enclosure Installation 1. The enclosure is to be mounted on a pole or a building that

is capable of supporting a minimum of 10 lbs.

2. Position the enclosure so that the LED display is clearly visible for the operator

3. Install conduit seal-off fittings for ALL electrical connections at the box

4. Installation must comply with the local electric code.

WARNING: Before any welding is attempted, disconnect all wires going to the circuit board.

PLC/ Scada Connection

1. Make the connections from the RTU/PLC to the Run Status terminals (Port 4-5)

2. Make the connections from the RTU/PLC to the Alarm output terminal (Ports 6-7)

NOTE: These terminals are left un-touched if not used.

NOTE: Please see operation table on page 27.

Moun ng Hardware

Unistrut Clamp

Unistrut

Actuator Valve Installation

1. Install the SureFire approved Actuator Valve

2. Terminate the Actuator wires (1, 2 and 3) at the Actuator Valve terminals (1, 2 and 3)

NOTE: Actuator 1 terminate @ SureFire 1

Actuator 2 terminate @ SureFire 2

Actuator 3 terminate @ SureFire 3

NOTE: Must use SureFire Actuator valve or an actuator approved by SureFire.

WARNING: Before terminating any wires, be sure no power is supplied to the controller.

NOTE: After completing your installation and confirming proper operation, lock or tag your control unit box to prevent unwanted or unauthorized modifications.

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INSTALLATIONGUIDE

RTD 1. Install the RTD into the provided thermo-well on the

vessel.

2. Connect the two negative wires to the negative termi-nals (Ports10-11) on the circuit board.

3. Connect the one positive wire to the positive terminal (Port 12).

4-20mA

The proper connection method for the 4-20mA remote circuit monitoring is as follows

1. Ensure there is no power to the BMS-350 or PLC before con-necting the wires.

2. Connect positive side of the power supply from the remote monitoring equipment to positive port and the negative wire to the negative port of the 4-20mA terminal.

3. If a 1-5 V signal is desired instead of the 4-20m, please install a 250 Ω resistor (at the remote moni-toring equipment) to the return in 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).

RTD Scaling: 4 mA = 0 °F 20 mA= 670 °F T/C Scaling: 4 mA = 32 °F 20 mA = 2400 °F

PLC/ Scada Connection (Cont.)

Solenoid Valve 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 1/4” NPT x 3/8” tubing fittings and connect the solenoid in-line.

5. Trim the unused GREEN wire short and cap it off with a wire nut as this will not be used.

6. Use the proper conduit and connectors and wire the solenoid to the SureFire system.

Stage 1 Solenoid terminated to ports 8 and 9.

Stage 2 Solenoid terminated to ports 18 and 19.

Note: Reference solenoid body for proper flow direction. 1 = Outlet 2 = Inlet

16

INSTALLATIONGUIDE

Shutdown/Standby Installation 1. Install a switching device in one of the assigned terminals

(Ports 20-21, 22-23 & 24-25)

2. If a switching device is not installed, place a jumper in the assigned terminals.

NOTE: Closed Contact = Clear

Open Contact = Activated

Solar Panel Installation 1. Install a 12 VDC solar panel and mount facing southeast.

2. Make the connection from the negative side of the solar panel to the negative terminal (Port 32)

3. Make connect from the positive side of the solar panel to the positive terminal (Port 33)

NOTE: Internal regulator to trickle charge 12VDC battery.

NOTE: 75 Watt solar panel is the max allowable solar panel

size

Proof of Valve Closure 1. Install a main burner valve with a switch to provide proof

of closure and terminate at ports 26 & 27.

2. If not used, place a jumper in the assigned terminal. NOTE: Do Not use as a Shutdown

Thermocouple Installation 1. If using a thermocouple for temperature control, make

the connection from the positive lead of the thermocouple (yellow) to the positive terminal, (Port 13) and the negative lead of the thermocouple (red) to the negative terminal (Port 14).

2. If using a thermocouple for a high temperature shutdown, make the connection from the positive lead of the thermocouple (yellow) to the positive terminal (Port 15) and the negative lead of the thermocouple (red) to the negative terminal (Port 16).

NOTE: If not using the Thermocouple high temp shut-down, place jumper in termination port 15 & 16.

17

INSTALLATIONGUIDE

NOTE:

If utilizing 12 VDC power supply, set voltage @ 13.4 VDC. Power supply should be rated for

90 + watts

SureFire Ignition Unit

1. Ensure all supply gas is turned off and locked out/ tagged out.

2. Install the FT unit in the fire tube.

3. The igniter has two wires that are white in color. These wires are not polar sensitive. Terminate wires to ports 30 and 31.

4. Verify continuity for all wiring prior to reinstalling burner into the fire tube.

Flame Sensing Flame sensing mechanism will be dependent on the ignition unit being utilized.

For flame rod flame sensing terminate flame rod wire at des-ignated port on upper left hand corner of the circuit board.

Isolated grounding is required. Terminate ground wire to cir-cuit board labeled Chassis Ground and ground screw on GUA on arrestor housing.

NOTE: Please do not bond the flame sensing ground to facility ground to avoid flame sensing disruption.

For thermocouple flame sensing terminate the red (-) wire and yellow (+) to the designated ports in the upper left corner of the circuit board.

Battery Installation 1. Install a 12 VDC SLA battery within an enclosure separate of the

BMS-350 enclosure

2. Make the connection from the negative side of the battery to the negative terminal (Port 34)

3. Make the connection from the positive side of the battery to the positive terminal (Port 35)

4. Install a circuit breaker/disconnect switch rated @ 10 amps, inline between the battery and the circuit board for an accessible discon-nect of power.

18

INSTALLATIONWIRINGDIAGRAM

19

FUELTRAINDIAGRAMS

Piloted Fuel Train

Pilotless Fuel Train

20

CONTROLLERSETUP

High Temperature

Primary Function:

The High Temp button displays the current high temperature setting.

To set or change the High Temperature, follow these steps:

1. Press the high temp button to view current high temperature setting.

2. Unlock the system by pressing and holding the up arrow button for 5 seconds until a series of zeros

appears.

3. Press and hold the high temp button and use the up or down arrow buttons to adjust the tempera-

ture setting. (Press and hold the up or down arrows for 5 seconds to scroll).

NOTE: High temp factory setting: RTD = 120°F / TC = 1800°F

High temp range: RTD = 34°F — 590°F / TC = 34°F — 2400°F

Secondary Function:

The High Temp button displays the safety thermocouple’s current temperature when pressed and held for

5 seconds in the locked mode.

Low Temperature The Low Temp button displays the current low temperature setting.

To set or change the Low Temperature, follow these steps:

1. Press the low temp button to view current low temperature setting.

2. Unlock the system by pressing and holding the up arrow for 5 seconds until a series of zeros

appear.

3. Press and hold the low temp button and use the up or down arrow buttons to adjust the temperature

setting. (Press and hold the up or down arrows for 5 seconds to scroll.)

NOTE: Low temp factory setting: RTD = 100°F / TC = 1300°F

High temp range RTD = 32°F — 588°F / TC = 32°F — 2398°F

NOTE: The SureFire System comes standard with a built in minimum 2° F temperature span to prevent

undue wear associated with equipment short cycling.

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Flame Sense (F/H) The Flame Sense button displays the current flame sensing device.

To set or change the flame sensor, follow these steps:


appear.

2. Press and hold the flame sense button, use the up and down arrow buttons to select desired flame

sensing mechanism. F = Flame Rod / H = Thermocouple.

NOTE: Flame Sense factory setting: F (Flame Rod)

CONTROLLERSETUP

Flame Strength Primary Function:

The Flame Strength button displays the current flame strength value for the Flame Rod and temperature

for the Thermocouple.

To check flame strength when using a Flame Rod.

1. Press the flame strength button.

When no flame is present, the value will be above 500.

When flame is present the value will be below 6.

To check flame strength when using a Thermocouple.

1. Press the flame strength button.

On a initial start-up when the thermocouple is cold the temperature will read 70.

When the flame is not present, the system observes a decrease in temperature to sense a

flame out.

When the flame is present, the system observes an increase in temperature to sense a flame.

Secondary Function:

The Flame Strength button displays the Safety Thermocouple temperature shutdown setting when pressed

and held for 5 seconds. To set or change the Safety Thermocouple temperature shutdown, follow these steps:

1. Press the Flame Strength button to view current thermocouple temperature.

2. Unlock the system by pressing and holding the up arrow for 5 seconds until a series of zeros

appear.

3. Press and hold the Flame Strength button and use the up and down arrow buttons to adjust to

desired temperature.

NOTE: The Safety Thermocouple factory setting: 300°F

The Safety Thermocouple range: 40°F — 2400°F

22

CONTROLLERSETUP

Extreme High Temp Delta (EHTD) The EHTD button displays the current Extreme High Temp Delta setting.

To set or change the EHTD, follow these steps:

1. Press the EHTD button to view the current delta setting


appear

3. Press and hold the EHTD button and use the up and down arrow buttons to adjust to desired delta.

NOTE: EHTD factory setting: 50.

EHTD range when using RTD as temp control: 10°F — 520°F

EHTD range when using T/C as temp control: 10°F — 1000°F

Temp Control A/1/2 The Temp Control A/1/2 button displays the current input control device.

The system can be controlled by three different input devices: RTD, Thermocouple, or ALT SENSE IN-

PUT.

To set or change the input control device use the following steps:

1. Press the Temp Control A/1/2 button to view the current setting.

A = ALT SENSE INPUT / 1 = RTD / 2 = THERMOCOUPLE


appear.

3. Press and hold the Temp Control A/1/2 button and use the up and down arrow buttons to select

desired setting.

NOTE: Temp Control A/1/2 factory setting is 1.

NOTE: An example of a ALT SENSE INPUT device switch, could be a pressure switch or a dry contact

from a PLC/RTU device.

23

CONTROLLERSETUP

Pilot Mode (1/2) The Pilot Mode 1/2 button displays the current pilot mode.

The system has two pilot mode option when used in a piloted application, Intermittent or Standing Pilot

To set or change the Pilot Mode option, please follow these steps:

1. Press the Pilot Mode button to view the current option

1 = Intermittent Pilot / 2 = Standing Pilot


appear.

3. Press and hold the Pilot Mode button and use the up and down arrow buttons to select desired set-

ting.

NOTE: Pilot mode factory setting is 1.

Flame Proof Timing (FPT) The FPT button displays the current flame proof timing between the opening of the first stage solenoid and

when the system stops looking for a flame.

To set or change the flame proof timing, follow these steps:

1. Press the FPT button to view the current timing.


appear.

3. Press and hold the FPT button and use the up and down arrow buttons to select desired timing.

NOTE: FPT factory setting: 15 seconds.

FPT range: 15 — 60 seconds.

24

CONTROLLERSETUP

Auxiliary (AUX) Primary Function:

The AUX button displays the current ohms / resistance on the igniter

Secondary Function:

The AUX button displays the following information: System Days On, Main Burner Hours On, Ignition

Attempts, and Successful Ignitions.

To view the above information, follow these steps:

1. Press and hold the AUX button and press the up arrow button once provides the number of days the

system has been in operation.

2. Press and hold the AUX button and pressing the up arrow button twice provides the number of days

the main burner has been burning.

3. Press and hold the AUX button and pressing the up arrow button three times provides the number

of ignition attempts.

4. Press and hold the AUX button and pressing the up arrow button four times provides the number of

successful ignitions.

Solenoid Timing The Solenoid Timing button displays the current timing between the first stage solenoid opening and the

second stage solenoid opening.

To set or change the solenoid timing, follow these steps:

1. Press the Solenoid Timing button to view the current timing.


appear.

3. Press and hold the Solenoid Timing button and use the up and down arrow buttons to select desired

timing.

NOTE: Solenoid Timing factory setting: 30 seconds.

Solenoid Timing range: 5 — 60 seconds

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Battery Volts The Battery Volt button displays the current voltage being delivered to the controller by the power supply.

To view the current voltage of the power supply, press the Battery Volt button.

Power Supply The SureFire controller accepts rated voltages as described in the specification, page 34. No setup is required.

However, the system does have a built-in volt meter to measure battery voltage at all times. To check the bat-

tery volts, press the battery volts button. This can be helpful in troubleshooting, but will not replace a battery

load tester.

WARNING : If the battery volts drop below 11 volts at any time, a shutdown will occur on code 13.

Status Code Primary Function:

The Status Code button displays the code that corresponds with the current unit status.

To observe the status of the system, press the status code button to view the current code displayed on the

screen. Codes are printed on the overlay of the controller.

Secondary Function:

The Status Code button displays the past 9 error codes. To view the last 9 error codes, follow these steps:

1. Press and hold the status code button and use the up and down arrow buttons to view the past 9

error codes.

CONTROLLERSETUP

26

OPERATIONSGUIDE

Status Codes

Run Codes Description

00 System running, no errors

01 Waiting for startup signal

02 Pre-purge on Startup

07 Purge between Ignition Attempts

08 Waiting for stage 2 solenoid valve to open

Standby Codes Description

09 Standby Interloop

10 Loss of Fuel Gas

Shutdown Error Codes Description

11 Manual Shut Off

12 Max Retries Exceeded

13 Low Battery Volts The low voltage cut off for the system is @ 10.6 Volts

14 Igniter Short Circuit

15 Igniter Open Circuit

16 Flame Sensed Before Startup, FR Short

17 RTD or T/C Error or Disconnected

Temp for RTD < 1°F or > 655 °F

Temp for TC > 2650 °F

18 Extreme High Temp

19 Shutdown Interlock

20 Main Fuel Valve Failure

21 Replace FT-Ignition Unit

22 Stage 1 Solenoid Disconnected

23 T/C High Temp Shutdown

27

OPERATIONSGUIDE

Function: Parameters:

RTD High Temp 34 °F — 590 °F

TC Low Temp 32 °F — 2398 °F

TC High Temp 34 °F — 2400 °F

Safety Thermocouple 40 °F — 2400 °F

FPT (Flame Proof Timing) 15 seconds — 60 seconds

Solenoid Timing 5 seconds — 60 seconds

EHTD 10 °F — 1000 °F

Set Point Parameters

RTD Low Temp 32 °F — 588 °F

Operational Situations

Operational State Alarm Run Status Red LED Green LED

Blue LED Amber LED

System OFF or Manual Shutdown

Open Open ON OFF OFF OFF

System ON, Pre-purge

complete, Igniter On Close Open OFF ON OFF ON

Flame sensed, Burner run-ning No Errors

Close Close OFF ON ON OFF

Shutdown, Igniter Error Open Open Blinking OFF OFF Blinking

Stand By Error Close Open OFF Blinking OFF OFF

Shutdown Interlock Open Open Blinking OFF OFF OFF

28

INTERMITTENTPILOTOPERATION

Ignition Process - Intermittent Pilot 1) Unlock system 2) Set desired parameters 3) Press the ON button 4) Pre-purge on Start-up- 60 second countdown displayed - Green LED ON 5) Audible Alarm - 5 second countdown displayed - Green LED ON 6) Igniter - 8 second countdown displayed - Green and Amber LED ON 7) Stage 1 Solenoid/Actuator valve opens - igniter remains on - Green and Amber LED ON 8) Ignition is achieved, flame is sensed - Green and Blue LED ON 9) Stage 2 solenoid valve opens - timing between solenoids expires - Green and Blue LED ON 10) Unit is now running - Status code 00 - Green and Blue LED ON 11) Process Temperature exceeds High Temp Set point - Stage 1 and Stage 2 solenoids close - Green LED ON 12) Process Temperature reduced to Low Temp Set point - Restart at step 5

Re-Ignition Process - No Flame Sensed 1) Once the system recognizes that no flame is sensed, the system will automatically begin the ignition

process. 2) Purge between ignition attempt - 120 second countdown - Green LED ON 3) Reference step 5 - 12 in the “Ignition Process Section”

NOTE: If system fails to prove a flame on the fourth attempt, the system shuts down on code 12. Blinking Red LED

Re-Ignition Process - Standby 1) System in Standby - Blinking Green LED 2) Once the system resolves the Standby issue, the system will automatically begin the ignition process. 2) Pre-purge on Start-up - 120 second countdown - Green LED ON 3) Reference step 5 - 12 in the “Ignition Process Section”

Re-Ignition 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 is resolved, manual reset is required. Press the OFF and ON button to reset. 4) Pre-purge on Start-up - 120 second countdown - Green LED ON 5) Reference step 5 - 12 in the “Ignition Process Section”

29

INTERMITTENTPILOTOPERATION

Flow Chart

30

STANDINGPILOTOPERATION

Ignition Process - Standing Pilot 1) Unlock system 2) Set desired parameters 3) Press the ON button 4) Pre-purge - 60 second countdown displayed - Green LED ON 5) Audible Alarm - 5 second countdown displayed - Green LED ON 6) Igniter - 8 second countdown displayed - Green and Amber LED ON 7) Stage 1 Solenoid/Actuator valve opens - igniter remains on - Green and Amber LED ON 8) Ignition is achieved, flame is sensed - Green and Blue LED ON 9) Stage 2 solenoid valve opens - timing between solenoids expires - Green and Blue LED ON 10) Unit is now running - Status code 00 - Green and Blue LED ON 11) Process temp exceeds High Temp Set point - Stage 2 solenoid valve closes but Stage 1 solenoid valve re-

mains open - Green and Blue LED ON 12) Process Temperature reduced to Low Temp Set point - Restart at step 9

If the process temperature exceeds the high temp set point by 10 ⁰F, the stage 1 solenoid valve will close - Green LED ON - The system will restart at step 5 once process temperature is reduced to low temp set point




Re-Ignition Process - Standby 1) System in Standby - Blinking Green LED 2) Once the system resolves the Standby issue, the system will automatically begin the ignition process. 2) Pre-purge on Start-up - 120 second countdown - Green LED ON Reference step 5 - 12 in the “Ignition Process Section

Re-Ignition 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 is resolved, manual reset is required. Press the OFF and ON button to reset. 4) Pre-purge on Start-up - 120 second countdown - Green LED ON 5) Reference step 5 - 12 in the “Ignition Process Section”

31

STANDINGPILOTOPERATION

Flow Chart

32

PILOTLESSOPERATION

Ignition Process - Pilotless 1) Unlock system 2) Set desired parameters 3) Press the ON button 4) Pre-purge - 60 second countdown displayed - Green LED ON 5) Audible Alarm - 5 second countdown displayed - Green LED ON 6) Igniter - 8 second countdown displayed - Green and Amber LED ON 7) Stage 1 Solenoid/Actuator valve opens - igniter remains on - Green, Blue, and Amber LED ON 8) Ignition is achieved, flame is sensed - Green and Blue LED ON 9) Unit is now running - Status code 00 - Green and Blue LED ON 10) Process temp exceeds High Temp Set point - Stage 1 solenoid valve closes - Green LED ON 11) Process Temperature reduced to Low Temp Set point - Restart at step 5

On a pilotless system, the Stage 2 Solenoid is not used.




Re-Ignition Process - Standby 1) System in Standby - Blinking Green LED 2) Once the system resolves the Standby issue, the system will automatically begin the ignition process. 2) Pre-purge on Start-up - 120 second countdown - Green LED ON Reference step 5 - 10 in the “Ignition Process Section

Re-Ignition 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 is resolved, manual reset is required. Press the OFF and ON button to reset. 4) Pre-purge on Start-up - 120 second countdown - Green LED ON 5) Reference step 5 - 10 in the “Ignition Process Section” NOTE: Keep Pilot Mode in Mode 1 when application calls for PILOTLESS.

33

PILOTLESSOPERATION

Flow Chart

34

SPECIFICATIONS

Power Supply Specifications Device Specification

Battery 12 VDC - 14.5 VDC

12 VDC Power Supply Set @ 13.4 VDC

Solar Panel 12.0 VDC Only — 75 Watt MAX

24VDC Input 24.0VDC

Ignition Unit Specifications Ignition Unit @ Max 6.0 Amps

Ignition Unit @ Steady state 1.5 Amps — 2.0 Amps

Sensor Specifications RTD 0 ⁰F — 670 ⁰F

Thermocouple 32 ⁰F — 2400 ⁰F

ALT Sense Switch Dry Contact Switch (Open / Close loop)

Standby Switches Dry Contact Switch (Open / Close loop)

Shutdown Switches Dry Contact Switch (Open / Close loop)

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

Outputs 4-20mA 12-24 VDC for 4-20mA Output

Run Status (Output) 12-24 VDC @ 1 Amp

Max Volts: 26 VDC, Max Current: 1 Amp

Alarm (Output) 12-24 VDC @ 1 Amp

Max Volts: 26 VDC, Max Current: 1 Amp

Power Supply and Igniter Wiring Requirements

14AWG @ 20 ft.

NOTE: If distance from battery (power supply) is further than 20 feet, a larger gauge of wire is required.

35

TROUBLESHOOTINGGUIDE

RUN CODES

Code Symptom Action Visual

00 System Running

Pilot/Main burner is ON.

No errors are present.

1. Normal operation 2. Process getting up to

temperature

Green & Blue LED ON.

01 Waiting for

Startup Signal

Pilot/Main burner not running.

1. Normal operation. 2. Temperature is within

High / Low temp setting.

Green LED ON.

02 Pre-purge on

startup


1. Normal operation. 2. Unit is preparing to

attempt ignition. 3. 120 second countdown is

occurring on display.

Green LED ON.

07 Purge between

Ignition Attempts


Previous ignition attempt failed.

1. Normal operation. 2. Unit attempting to re-

ignite. 3. 120 second countdown is

occurring on display.

Green LED ON.

08 Waiting for Stage 2

Valve to open

Pilot flame is present, (Piloted system)

Main burner is present, (Pilotless system)

Stage 1 solenoid is open

1. Normal operation. 2. System is ON and flame

is proven. 3. Waiting for second stage

solenoid to open.

Green & Blue LED ON.

36


STANDBY CODES


09 Standby Interloop


No activity when attempting startup.

Ports 20 and 21 have been activated.

1. System detecting an open circuit.

2. Customer supplied switch is activated.

3. Check switching device for faulty operation.

4. Verify wiring from switching device.

5. Verify jumper is installed. 6. Jumper is required if function

is not being utilized

Blinking Green LED.

10 Loss of Fuel Gas



Ports 22 and 23 have been activated.

1. System detecting an open circuit

2. Customer supplied switch is activated.

3. Check switching device for faulty operation.

4. Verify wiring from switching device.

5. Verify jumper is installed. 6. Jumper is required if function

is not being utilized

Blinking Green LED.

37


SHUTDOWN CODES


11 Manual Shut Off


1. System has been turned OFF Manually.

2. System has been turned OFF remotely by a momentary switch signal to the Remote OFF terminal, ports 15 & 16.

Red LED ON.

12 Max Retries

Exceeded


1. Unit has attempted and failed to prove a flame 4 consecutive times.

2. Verify proper fuel pressure, air/ fuel mixer settings and amperage to igniter.

3. Verify proper valve operation: solenoids, slow flow valve, diaphragm valve, actuator valve, etc.

4. Verify ground when using a flame rod for flame sensing.

5. Air cell restricting O2 to air/fuel mixers.

6. Plugged orifice on pilot and main burner.

7. Kimray T-12 improperly set.

Blinking Red LED.

13 Low Battery Volts



1. Battery or power supply below minimum voltage required to operate system.

2. Verify power supply. 3. Verify battery volts is = or

>11.0 volts. 4. Charge or replace battery if

required. 5. Check solar panel for faulty

operation.

Blinking Red LED.

38


SHUTDOWN CODES Cont.


14 Igniter Short Circuit


System will proceed through countdown but will shutdown after countdown is complete.

1. Verify igniter wires are not making contact with each other or ground.

Blinking Red and Amber LEDs.

15 Igniter Open Circuit


System will proceed through countdown but will shutdown after countdown is complete.

1. System detecting an open circuit upon initial start-up.

2. Verify wiring termination on ports 30 and 31.

3. Damage Igniter element.

Blinking Red and Amber LEDs.

16 Flame Sensed before startup,

FR Short



1. System detecting a close circuit for flame rod sensor upon initial start-up.

2. Inspect for leaking control valve.

3. Solenoid valve not closing. 4. Verify flame rod and/or flame

rod wire is not contacting ground.

5. Verify circuit board is not ex-posed to moisture.

6. Flame rod sensor failure, contact SureFire Tech for support.

Blinking Red LD

17 RTD or TC Error or Disconnected



1. System detecting a disconnect upon initial start-up.

2. Verify RTD/TC are properly terminated.

3. Verify RTD/TC wires are not shorting.

4. RTD/TC failure. 5. Process Temp below 1°F

(RTD).

Blinking Red LED

39




18 Extreme High

Temp



1. Process temperature has exceed EHTD setting.

2. Inspect for leaking control valves. 3. Solenoid valve not closing.

Blinking Red LED

19 Shutdown Interlock



Ports 24 and 25 are activated.


2. Customer supplied switch is activated. 3. Check switching device for faulty oper-

ation. 4. Verify wiring from switching device. 5. Verify jumper is installed. 6. Jumper is required if function is not be-

ing utilized

Blinking Red LED

20 Main Fuel

Valve Failure





2. Customer supplied switch on main burner control valve has detected an unsafe condition.

2. Customer supplied switch is activated. 3. Check switching device for faulty oper-

ation. 4. Verify wiring from switching device. 5. Verify jumper is installed. 6. Jumper is required if function is not be-

ing utilized 7. DO NOT USE AS SHUTDOWN.

Blinking Red LED

21 Replace FT

Ignition Unit



1. Igniter Ohms exceeded 4 Ohms 2. Igniter has deteriorated causing high

ohms.

Blinking Red LED.

40



22 Stage 1 solenoid

valve disconnected




2. Check device for faulty operation. 3. Verify wiring from device. 4. System detecting battery volts below

12V. 5. Verify battery voltage.

Blinking Red LED.

23 T/C High Temp

Shutdown





2. Check device for faulty operation. 3. Verify wiring from device. 4. Jumper is required if function is not be-

ing utilized. 5. Verify jumper is installed.

Blinking Red LED.


41

MODBUSINFORMATION

Programming Information for Surefire BMS-350 with Modbus Interface

(Firmware Name: Modbus 350)

6 May 2019 This document describes the programming interface for the BMS-350 burner controller using the Modbus interface board. The Modbus registers, their contents, command sequencing and examples of command exe-cution over Modbus are described.

This document applies to firmware revisions 1.9. In order to use Modbus 1.9, the BMS-350 must be upgraded to firmware package 2.6.

1.0 Introduction The Modbus interface to the BMS-350 is accomplished via an intermediary processor board, the BMS Mod-bus board. The function of this board is to serve as a Modbus RTU slave, handling requests from the Modbus master to read information and relay command data to the BMS-350 board.

The Modbus board behaves as a specialized “mailbox”; a set of Modbus holding registers is available in the Modbus board, any of which can be read or written by either the BMS board or the Modbus master. This ar-rangement relieves the BMS board of the job of hosting the Modbus and relaxes many of the timing con-straints that would overtax the limited hardware resources on the BMS board MCU.

A number of the registers are constantly updated by the BMS board with information such as temperatures, modes, output states, ignition attempts, and other important data. These should be treated as read-only by the Modbus master. Other registers are defined as command and parameter registers to be written by the Modbus master to cause the BMS board to perform an action or set an operational variable (such as high temperature limit).

Both RS-485 and RS-232 interfaces are available for use by the Modbus master. Only one of these interfaces can be selected for use at any given time via the configuration DIP switch. The configuration DIP switch also sets the Modbus address and the baud rate.

LEDs are present on the Modbus board to indicate processing of Modbus packets (from the Modbus side) and BMS-350 packets (from the BMS-350 side). The LEDs illuminate when intact packets are received and are being processed. Under normal operation the LED on the BMS side should show regular activity as it updates the holding registers on the Modbus board and queries for command data. The LED on the Modbus side will only show activity if the Modbus master is reading from or writing to the Modbus board.

2.0 Amber LED Indication There are two LEDs in the Modbus circuit board that indicates different operations

COM LED:

This LED indicates that the Modbus circuit board is communicating and sending data packages to the BMS-350 circuit board. This LED is located between the MCU chip and the large terminal block and is ;labeled COM. BMS COM LED:

This LED indicates that the BMS-350 is communicating and sending data packages to the Modbus circuit board. This LED is located between the MCU chip and the small terminal block and is labeled BMS COM.

42

MODBUSINFORMATION

3.0 Basic read/write operation Basic operation of the BMS-350 with Modbus is as follows:

For reading a register (or registers) the Modbus master sends a holding register read request to the BMS Mod-bus board using Modbus Function 03 (see “MODBUS APPLICATION PROTOCOL SPECIFICATION V1.1b”, www.modbus.org for more detailed information about the Modbus protocol and functions). The Mod-bus board will respond with the contents of the requested registers. There are currently 256 registers defined (Modbus addresses 40001 thru 40256), but not all are used. Attempts to read registers outside that address space will return an error according to the Modbus protocol.

While the Modbus board is servicing a read request from the master, it is unable to service simultaneous read requests from the BMS board for command data. This may result in the BMS board waiting for access and may result in a blinking LED display on the BMS board. For this reason, it is best for the master to refrain from reading a large number of registers in a single request, and also to avoid issuing rapid read requests. It is suggested that read requests be limited to about 10 registers or less at a time, with a maximum read rate of a few Hz.

For writing a register, the Modbus master sends a holding register write request to the BMS Modbus board using Modbus Function 6 (write single register) or Modbus Function 16 (write multiple registers). The sup-plied data will be written to the specified register.

The following table is the register map for the BMS-350. Bits are in MSB first order.

Modbus address

Register name Modbus master does

R (Read) or RW (Read or Write)

Data type Notes

40001 System Mode(R) unsigned int 16

See mode table

40002 Process temperature(R)

unsigned int 16

Bit 9..0 is 0-511 degrees (RTD) Bit 9..0 is 0-2400 degrees (Thermocouple)

40003 High temperature limit(R)

unsigned int 16


40004 Low temperature limit(R)

unsigned int 16


43

MODBUSINFORMATION

Modbus address



Data type Notes

40005 Configuration and sta-tus(R)

unsigned int 16

Bit 0 – Light status 0 : RED light is on solid 1 : GREEN light is on solid Bit 1 – Temperature units 0 : Degrees C 1 : Degrees F Bit 2 – Input sense 0 : RTD 1 : ALT (pressure switch) Bit 3 - Igniter volts 0 : 14V 1 : 13V Bit 4 – Pilot mode 0 : Intermittent pilot 1 : Standing pilot Bit 5 – Flame sensed 0 : No flame sensed 1 : Flame sensed Bit 6 – Factory use only Bit 7 – Factory use only Bit 8 – Spare standby #1 0 : Clear 1 : Activated (GREEN light blinking) Bit 9 – 2pare standby #2 0 : Clear 1 : Activated (GREEN light blinking) Bit 10 – Shutdown interlock 0 : Clear 1 : Activated (RED light blinking) Bit 11 – ESD status 0 : Clear 1 : Activated (RED light blinking) Bit 12 – Standby interlock 0 : Clear 1 : Activated (GREEN light blinking) Bit 13 – Factory use only Bit 14 – Factory use only Bit 15 – Factory use only

40006 Average battery volt-age(R)

unsigned int 16

Bit 7.0 is 0 to 25.5 volts

40007 Burn time(R) unsigned int 16

Hours, rolls over at 9999

40008 Number of attempts(R) unsigned int 16

Rolls over at 9999

44

MODBUSINFORMATION

Modbus address



Data type Notes

40009 Number of successes(R)

unsigned int 16

Rolls over at 9999

40010 Command status(R) unsigned int 16

0x55 IDLE - Ready for new command 0x01 Command executed OK 0x02 Bad command, nothing done 0x03 BMS read of exec reg from Modbus board timed out 0x04 BMS read of exec packet from Modbus board had bad checksum 0x05 BMS read of cmd reg from Modbus board timed out 0x06 BMS read of cmd packet had bad checksum 0x07 Command number not recognized 0x08 BMS read of param reg from Modbus board timed out 0x09 BMS read of param packet had bad checksum 0x0A Parameter out of limits for command 0x0B BMS 350 Controller is locked 0x0C Unknown status code returned from Modbus board read attempt

40011 Command number(RW)

unsigned int 16

0x01 – Unlock – same as pressing unlock sequence on keypad. Display function and timeout exactly the same as if done from keypad. No parameter required. 0x02 – Set low temperature limit. Behaves as if done from the keypad. Requires parameter in the format of register 40004. 0x03 – Set high temperature limit. Behgaves as if done from the keypad. Requires parameter in the for-mat of register 40003. 0x04 – Turn ON. Behaves as if keypad ON button were pressed. No parameter required. 0x05 – Turn OFF. Behaves as if keypad OFF button were pressed. No parameter required. 0x06 – Set flame strength threshold. Behaves as if done from the keypad. Requires a parameter in the form of an 11-bit unsigned integer.

40012 Command parameter(RW)

unsigned int 16

Parameter for command (if required, ignored if not required). May also be interpreted as “command value”.

45

MODBUSINFORMATION

Modbus address



Data type Notes

40013 Command execute(RW)

unsigned int 16

Set to non-zero to request that the command in regis-ter 40011 be executed with the parameter in register 40012(if needed). Will continue to execute until set to zero.

40014 thru 40019

Unallocated unsigned int 16

Read as zero, can be written but will be ignored

40020 Bit 0 – Light status 0:RED light is on solid 1:GREEN light is on solid

unsigned int 16

Bit #0 of register 40005 unpacked into a single regis-ter for use by controllers with primitive bit manipula-tion capabilities.

40021 Bit 1 – Temperature units 0 : Degrees 1 : Degrees F

unsigned int 16


40022 Bit 2 – Input sense 0 : RTD 1 : ALT (pressure switch)

unsigned int 16


40023 Bit 3 - Igniter volts 0 : 14V 1 : 13V

unsigned int 16


40024 Bit 4 – Pilot mode 0 : Intermittent pilot 1 : Standing pilot

unsigned int 16


40025 Bit 5 – Flame sensed 0 : No flame sensed 1 : Flame sensed

unsigned int 16


40026 Bit 6 – Factory use on-ly

unsigned int 16


40027 Bit 7 – Factory use on-ly

unsigned int 16


46

MODBUSINFORMATION

Modbus address



Data type Notes

40028 Bit 8 – Spare standby #1 0 : Clear 1 : Activated (GREEN light blinking)

unsigned int 16


40029 Bit 9 – 2pare standby #2 0 : Clear 1 : Activated (GREEN light blinking)

unsigned int 16


40030 Bit 10 – Shutdown in-terlock 0 : Clear 1 : Activated (RED light blinking)

unsigned int 16

Bit #10 of register 40005 unpacked into a single reg-ister for use by controllers with primitive bit manipu-lation capabilities.

40031 Bit 11 – ESD status 0 : Clear 1 : Activated (RED light blinking)

unsigned int 16


40032 Bit 12 – Standby inter-lock 0 : Clear 1 : Activated (GREEN light blinking)

unsigned int 16


40033 Bit 13 – Factory use only

unsigned int 16



unsigned int 16



unsigned int 16


40036 Flame sense T/C Tem-perature

unsigned int 16

Bit 9..0 is 0-2400 degrees (Thermocouple)

47

MODBUSINFORMATION

Modbus address



Data type Notes

40038 Safety T/C Tempera-ture Threshold

unsigned int 16


40039 thru 40249

Unallocated unsigned int 16

Read as zero, can be written but will be ignored

40250 BMS diagnostics regis-ter #1 (R)

unsigned int 16

Factory use only

40251 BMS diagnostics regis-ter #1(R)

unsigned int 16

Factory use only

40252 BMS read count (R) unsigned int16

Number of packets sent by the BMS board to the Modbus board to read the contents of a holding reg-ister

40253 Modbus board firm-ware revision (R)

unsigned int16

High byte: uint8 – major release number Low byte: uint8 – minor release number Ex: Version 1.7 will exhibit 0x17

40254 Modbus read count (R) unsigned int16

Number of function 03 requests from the Modbus master

40255 BMS write count (R) unsigned int16

Number of packets sent by the BMS board to the Modbus board to update the contents of a holding register

40037 Safety T/C Tempera-ture

unsigned int 16


48

MODBUSINFORMATION

4.0 Command operation Command operation on the BMS-350 utilizes the “mailbox” concept. The general sequence is as follows:

1. MASTER reads Command Status register (Modbus 40010). If it reads as 0x55 (IDLE) then proceed. Otherwise wait a short time (a few hundred ms would be reasonable) and poll that register again. Contin-ue to do so until the register reads as 0x55 (IDLE).

2. MASTER writes the Command Number register (Modbus 40011) with the desired command number. Note that the first command to be issued is likely 0x01 (UNLOCK) unless the BMS300 has already been unlocked and the unlock has not timed out.

3. If the desired command requires a parameter, MASTER writes the parameter data to the Command Pa-rameter register (Modbus 40012).

4. MASTER writes a non-zero value to the Command Execute register (Modbus 40013).

The next poll of the Command Execute register by the BMS board will tell it that the MASTER wants to exe-cute a command. The BMS board will read the command and parameter, execute the command if possible, and write a status code to the Command Status register.

5. MASTER polls the Command Status register (Modbus 40010). If the command executed without error, status code 0x01 (OK) will be returned. If an error occurred during reading or executing the command, the relevant status code will be returned. If the status code is 0x55 (IDLE), then wait a short time (a few hundred ms would be reasonable) and poll that register again. Continue to do so until the register returns a status code other than 0x55.

6. MASTER writes zero (0) to the Command Execute register (Modbus 40013). The next poll of the Command Execute register by the BMS board will tell it that the MASTER no longer needs to have the command executed. The BMS board will write 0x55 (IDLE) to the Command Status regis-ter.

7. MASTER polls the Command Status register (Modbus 40010). If it reads 0x55 (IDLE) then proceed. Otherwise wait a short time (a few hundred ms would be reasonable) and poll that register again. Contin-ue to do so until the register reads as 0x55 (IDLE).

Note: when the Modbus master has written a non-zero value to the Command Execute register, the BMS-350 will continue to execute the command repeatedly at its internal command processing loop rate until the Modbus master writes a zero to the Command Execute register

49

MODBUSINFORMATION

Time step

Master's action BMS-350 action Registers

1 Read Command Status register. Is 0x55 (IDLE). Proceeds to next step.

40010 (status) 0x55 40011 (cmd) 0x00 40012 (param) 0x00 40013 (exec) 0x00

2 Write command to set high temp limit (0x03) to command number reg

40010 (status) 0x55 40011 (cmd) 0x03 40012 (param) 0x00 40013 (exec) 0x00

3 Write parameter (125F) to pa-rameter reg

40010 (status) 0x55 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x00

4 Request command execute by writing 0x01 to command exec reg


4 Sees command exec register with non-zero value. Reads command and parameter. Attempts to execute command. Fails since unit is locked. Writes LOCKED error code to command status reg.

40010 (status) 0x0B 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x01

5 Polls command status register. Sees LOCKED (0x0B) error code. Looks up error code and finds it must unlock the BMS-350 before changing the temp limit.


6 Write 0x00 to command exec reg.


7 Sees command exec register with zero value. Writes IDLE (0x55) to status register. Returns to idle state.


5.0 Example In the following example the Modbus master attempts to change the high temperature limit and then turn ON the BMS-350. The attempt to change the high temperature limit fails initially because the BMS-350 had not been unlocked. After the BMS-350 is unlocked, the temperature limit is changed and the unit is turned ON.

50

MODBUSINFORMATION

Time step


8 Reads command status register. Sees IDLE (0x55). Proceeds to next step.


9 Write command to unlock unit. 40010 (status) 0x55 40011 (cmd) 0x01 40012 (param) 0x7D 40013 (exec) 0x00



11 Sees command exec register with non-zero value. Reads command. Attempts to execute command. Succeeds in unlocking BMS-350 Writes OK code to command status reg.


12 Polls command status register. Sees OK (0x01). Proceeds to next step.




14 Sees command exec register with zero value. Returns to idle state.


15 Polls command status register. Sees IDLE (0x55). Proceeds to next step.


16 Write command to set high temp limit (0x03) to command number reg. Desired parameter is still in parameter register, so won't write it again.


51

MODBUSINFORMATION

Time step




18 Sees command exec register with non-zero value. Reads command and parameter. Attempts to execute command. Succeeds. Writes OK status code to command status reg.








22 Polls command status register. Sees IDLE (0x55). Proceeds to next step.


23 Write command to turn ON (0x04) to command number reg. No parameter needed. Existing parameter value will be ignored.




25 Sees command exec register with non-zero value. Reads command and parameter. Attempts to execute command. Succeeds. Begins turn-on sequence as if it were a keypad press. Writes OK status code to command status reg.


52

MODBUSINFORMATION

Time step








29 Polls command status register. Sees IDLE (0x55). All done!


6.0 DIP switch configuration and settings Switch SW1 on the Modbus board configures the Modbus address, baud rate, and selects the serial interface to be used. The notation “ON” and “OFF” follows from the direction of the arrow and the word “ON” located on the left side of the switch body near SW1-1. The switches are as follows:

Make sure at the receiving end, the following bits are set as: Data Bit = 8 Parity Bit = None Stop Bit = 1

Switch Selects Description

SW1-1 Modbus address bit 0 “ON” position is “1”, “OFF” is 0





SW1-6 Baud rate for communication with Modbus master “ON” is 19200, “OFF” is 9600

SW1-7 Unused Unused

SW1-8 Interface for communication with Modbus master “ON” is RS232, “OFF” is RS485

53

MODBUSINFORMATION

Desired Mod-bus address SW1-1 SW1-2 SW1-3 SW1-4 SW1-5

1 ON Off Off Off Off

2 Off ON Off Off Off

3 ON ON Off Off Off

4 Off Off ON Off Off

5 ON Off ON Off Off

6 Off ON ON Off Off

7 ON ON ON Off Off

8 Off Off Off ON Off

9 ON Off Off ON Off

10 Off ON Off ON Off

11 ON ON Off ON Off

12 Off Off ON ON Off

13 ON Off ON ON Off

14 Off ON ON ON Off

15 ON ON ON ON Off

16 Off Off Off Off ON

17 ON Off Off Off ON

18 Off ON Off Off ON

19 ON ON Off Off ON

20 Off Off ON Off ON

21 ON Off ON Off ON

22 Off ON ON Off ON

23 ON ON ON Off ON

24 Off Off Off ON ON

25 ON Off Off ON ON

26 Off ON Off ON ON

27 ON ON Off ON ON

28 Off Off ON ON ON

29 ON Off ON ON ON

30 Off ON ON ON ON

31 ON ON ON ON ON

The following table shows the switch settings for SW1-1 through SW1-5 required to obtain the desired Mod-bus address:

54

MODBUSINFORMATION

7.0 Troubleshooting information SYMPTOM: The LEDs on the BMS Modbus board do not flash.

DISCUSSION: The LEDs only flash when intact (complete and correct) packets are received from their re-spective interfaces. If the data arrives garbled, or if no data is sent, then the corresponding LED will not flash. The COM LED is between the MCU and the large terminal blocks, and is associated with activity on the Mod-bus. The BMS COM LED is between the MCU and the small terminal blocks, and is associated with activity on the BMS board.

POSSIBLE SOLUTIONS:

1. Verify that the cables or wires to the BMS Modbus board are connected.

2. Verify that the wires are connected to the correct pins.

3. Verify that the baud rate for data transmission is in agreement on both sides (for example, if the BMS Modbus board is set for 9600 baud, then the Modbus master must also be set for 9600 baud).

4. Verify that power is present at the BMS Modbus board.

5. If the Modbus COM LED doesn’t flash, verify that the Modbus master is sending read or write requests.

6. If the BMS COM LED doesn’t flash, verify that the BMS board has power. Under normal operation this LED should always be flashing if both boards are powered.

SYMPTOM: BMS-350 display flickers during Modbus operation

DISCUSSION: Due to the hardware constraints on the BMS-350, the LED display will flicker slightly during normal operation when the Modbus is in use. If the Modbus master polls the BMS-350 for data at a rapid rate, or transfers many registers during each poll, the flickering becomes worse. If the Modbus is being queried on a continuous basis, the display and keypad may become difficult to operate.

POSSIBLE SOLUTIONS:

1. Limit the number of registers being read from the BMS-350 during each transfer to about 10 or less.

2. Limit the polling interval to about twice per second.

SYMPTOM: Command status always reads 0x0B when attempting to execute a command

DISCUSSION: The BMS-350 board must be “unlocked” before any commands that modify the operational variables will succeed. This is similar to the front panel operation which requires a special sequence to unlock access to operational variables. A special command is used to allow the Modbus master to remotely unlock the BMS-350, command 0x01. The unlock will eventually timeout in the same manner as if done from the keypad.

POSSIBLE SOLUTIONS:

1. Execute an UNLOCK command (0x01) before attempting to execute any command that changes an opera-tional variable (e.g. sets a low temperature limit). See the example in Section 4.

Note: When changes are made, re-set/re-start system by powering OFF and powering back ON.

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SOFTWAREVERSIONS

Software Name Release Date Description

Modbus 350 5/6/2019 Standard base software

(Read / Write)

MODBUS

Software Version Release Date Description

V2.5 5/8/2019 Standard base software

BMS-350

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BMS-350 Installation and Operations Manual

10/19/2016

Last Update: 05/08/2019

Version 5.0

SureFire Farmington, NM Office:

1910 Rustic Place, Farmington, NM 87401 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

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