Proudly Made in the USA · BMS‐350 DESCRIPTION BMS-350 Circuit Board The SureFire BMS-350 system...
Transcript of 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
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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
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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
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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.
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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‐350DESCRIPTION
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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BMS‐350DESCRIPTION
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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BMS‐350DESCRIPTION
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
FT-4 Systems are suitable for pilotless 2” burner
applications, rated at 500,000 btu/H
FT-6 Systems are suitable for pilotless 3” burner
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”.
Please Contact SureFire for appropriate product part number.
Please Contact SureFire for appropriate product part number.
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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
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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.
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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.
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INSTALLATIONWIRINGDIAGRAM
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FUELTRAINDIAGRAMS
Piloted Fuel Train
Pilotless Fuel Train
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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:
1. Unlock the system by pressing and holding the up arrow button for 5 seconds until a series of zeros
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
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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
2. Unlock the system by pressing and holding the up arrow button for 5 seconds until a series of zeros
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
2. Unlock the system by pressing and holding the up arrow button for 5 seconds until a series of zeros
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.
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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
2. Unlock the system by pressing and holding the up arrow button for 5 seconds until a series of zeros
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.
2. Unlock the system by pressing and holding the up arrow button for 5 seconds until a series of zeros
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.
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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.
2. Unlock the system by pressing and holding the up arrow button for 5 seconds until a series of zeros
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
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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
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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 - 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 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 - 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 - 10 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 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
Pilot/Main burner not running.
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
Pilot/Main burner not running.
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
TROUBLESHOOTINGGUIDE
STANDBY CODES
Code Symptom Action Visual
09 Standby Interloop
Pilot/Main burner not running.
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
Pilot/Main burner not running.
No activity when attempting startup.
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
TROUBLESHOOTINGGUIDE
SHUTDOWN CODES
Code Symptom Action Visual
11 Manual Shut Off
Pilot/Main burner not running.
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
Pilot/Main burner not running.
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
Pilot/Main burner not running.
No activity when attempting startup.
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
TROUBLESHOOTINGGUIDE
SHUTDOWN CODES Cont.
Code Symptom Action Visual
14 Igniter Short Circuit
Pilot/Main burner not running.
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
Pilot/Main burner not running.
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
Pilot/Main burner not running.
No activity when attempting startup.
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
Pilot/Main burner not running.
No activity when attempting startup.
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
TROUBLESHOOTINGGUIDE
SHUTDOWN CODES Cont.
Code Symptom Action Visual
18 Extreme High
Temp
Pilot/Main burner not running.
No activity when attempting startup.
1. Process temperature has exceed EHTD setting.
2. Inspect for leaking control valves. 3. Solenoid valve not closing.
Blinking Red LED
19 Shutdown Interlock
Pilot/Main burner not running.
No activity when attempting startup.
Ports 24 and 25 are activated.
1. System detecting an open circuit upon initial start-up.
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
Pilot/Main burner not running.
No activity when attempting startup.
Ports 26 and 27 are activated.
1. System detecting an open circuit upon initial start-up.
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
Pilot/Main burner not running.
No activity when attempting startup.
1. Igniter Ohms exceeded 4 Ohms 2. Igniter has deteriorated causing high
ohms.
Blinking Red LED.
40
TROUBLESHOOTINGGUIDE
Code Symptom Action Visual
22 Stage 1 solenoid
valve disconnected
Pilot/Main burner not running.
No activity when attempting startup.
1. System detecting a disconnect upon initial start-up.
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
Pilot/Main burner not running.
No activity when attempting startup.
Ports 15 and 16 are activated.
1. System detecting a disconnect upon initial start-up.
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.
SHUTDOWN CODES Cont.
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
Bit 9..0 is 0-511 degrees (RTD) Bit 9..0 is 0-2400 degrees (Thermocouple)
40004 Low temperature limit(R)
unsigned int 16
Bit 9..0 is 0-511 degrees (RTD) Bit 9..0 is 0-2400 degrees (Thermocouple)
43
MODBUSINFORMATION
Modbus address
Register name Modbus master does
R (Read) or RW (Read or Write)
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
Register name Modbus master does
R (Read) or RW (Read or Write)
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
Register name Modbus master does
R (Read) or RW (Read or Write)
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
Bit #1 of register 40005 unpacked into a single regis-ter for use by controllers with primitive bit manipula-tion capabilities.
40022 Bit 2 – Input sense 0 : RTD 1 : ALT (pressure switch)
unsigned int 16
Bit #2 of register 40005 unpacked into a single regis-ter for use by controllers with primitive bit manipula-tion capabilities.
40023 Bit 3 - Igniter volts 0 : 14V 1 : 13V
unsigned int 16
Bit #3 of register 40005 unpacked into a single regis-ter for use by controllers with primitive bit manipula-tion capabilities.
40024 Bit 4 – Pilot mode 0 : Intermittent pilot 1 : Standing pilot
unsigned int 16
Bit #4 of register 40005 unpacked into a single regis-ter for use by controllers with primitive bit manipula-tion capabilities.
40025 Bit 5 – Flame sensed 0 : No flame sensed 1 : Flame sensed
unsigned int 16
Bit #5 of register 40005 unpacked into a single regis-ter for use by controllers with primitive bit manipula-tion capabilities.
40026 Bit 6 – Factory use on-ly
unsigned int 16
Bit #6 of register 40005 unpacked into a single regis-ter for use by controllers with primitive bit manipula-tion capabilities.
40027 Bit 7 – Factory use on-ly
unsigned int 16
Bit #7 of register 40005 unpacked into a single regis-ter for use by controllers with primitive bit manipula-tion capabilities.
46
MODBUSINFORMATION
Modbus address
Register name Modbus master does
R (Read) or RW (Read or Write)
Data type Notes
40028 Bit 8 – Spare standby #1 0 : Clear 1 : Activated (GREEN light blinking)
unsigned int 16
Bit #8 of register 40005 unpacked into a single regis-ter for use by controllers with primitive bit manipula-tion capabilities.
40029 Bit 9 – 2pare standby #2 0 : Clear 1 : Activated (GREEN light blinking)
unsigned int 16
Bit #9 of register 40005 unpacked into a single regis-ter for use by controllers with primitive bit manipula-tion capabilities.
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
Bit #11 of register 40005 unpacked into a single reg-ister for use by controllers with primitive bit manipu-lation capabilities.
40032 Bit 12 – Standby inter-lock 0 : Clear 1 : Activated (GREEN light blinking)
unsigned int 16
Bit #12 of register 40005 unpacked into a single reg-ister for use by controllers with primitive bit manipu-lation capabilities.
40033 Bit 13 – Factory use only
unsigned int 16
Bit #13 of register 40005 unpacked into a single reg-ister for use by controllers with primitive bit manipu-lation capabilities.
40034 Bit 14 – Factory use only
unsigned int 16
Bit #14 of register 40005 unpacked into a single reg-ister for use by controllers with primitive bit manipu-lation capabilities.
40035 Bit 15 – Factory use only
unsigned int 16
Bit #15 of register 40005 unpacked into a single reg-ister for use by controllers with primitive bit manipu-lation capabilities.
40036 Flame sense T/C Tem-perature
unsigned int 16
Bit 9..0 is 0-2400 degrees (Thermocouple)
47
MODBUSINFORMATION
Modbus address
Register name Modbus master does
R (Read) or RW (Read or Write)
Data type Notes
40038 Safety T/C Tempera-ture Threshold
unsigned int 16
Bit 9..0 is 0-2400 degrees (Thermocouple)
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
Bit 9..0 is 0-2400 degrees (Thermocouple)
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
40010 (status) 0x55 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x01
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.
40010 (status) 0x0B 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x01
6 Write 0x00 to command exec reg.
40010 (status) 0x0B 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x00
7 Sees command exec register with zero value. Writes IDLE (0x55) to status register. Returns to idle state.
40010 (status) 0x55 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x00
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.
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MODBUSINFORMATION
Time step
Master's action BMS-350 action Registers
8 Reads command status register. Sees IDLE (0x55). Proceeds to next step.
40010 (status) 0x55 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x00
9 Write command to unlock unit. 40010 (status) 0x55 40011 (cmd) 0x01 40012 (param) 0x7D 40013 (exec) 0x00
10 Request command execute by writing 0x01 to command exec reg
40010 (status) 0x55 40011 (cmd) 0x01 40012 (param) 0x7D 40013 (exec) 0x01
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.
40010 (status) 0x01 40011 (cmd) 0x01 40012 (param) 0x7D 40013 (exec) 0x01
12 Polls command status register. Sees OK (0x01). Proceeds to next step.
40010 (status) 0x01 40011 (cmd) 0x01 40012 (param) 0x7D 40013 (exec) 0x01
13 Write 0x00 to command exec reg.
40010 (status) 0x01 40011 (cmd) 0x01 40012 (param) 0x7D 40013 (exec) 0x00
14 Sees command exec register with zero value. Returns to idle state.
40010 (status) 0x55 40011 (cmd) 0x01 40012 (param) 0x7D 40013 (exec) 0x00
15 Polls command status register. Sees IDLE (0x55). Proceeds to next step.
40010 (status) 0x55 40011 (cmd) 0x01 40012 (param) 0x7D 40013 (exec) 0x00
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.
40010 (status) 0x55 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x00
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MODBUSINFORMATION
Time step
Master's action BMS-350 action Registers
17 Request command execute by writing 0x01 to command exec reg
40010 (status) 0x55 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x01
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.
40010 (status) 0x01 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x01
19 Polls command status register. Sees OK (0x01). Proceeds to next step.
40010 (status) 0x01 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x01
20 Write 0x00 to command exec reg.
40010 (status) 0x01 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x00
21 Sees command exec register with zero value. Returns to idle state.
40010 (status) 0x55 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x00
22 Polls command status register. Sees IDLE (0x55). Proceeds to next step.
40010 (status) 0x55 40011 (cmd) 0x03 40012 (param) 0x7D 40013 (exec) 0x00
23 Write command to turn ON (0x04) to command number reg. No parameter needed. Existing parameter value will be ignored.
40010 (status) 0x55 40011 (cmd) 0x04 40012 (param) 0x7D 40013 (exec) 0x00
24 Request command execute by writing 0x01 to command exec reg
40010 (status) 0x55 40011 (cmd) 0x04 40012 (param) 0x7D 40013 (exec) 0x01
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.
40010 (status) 0x01 40011 (cmd) 0x04 40012 (param) 0x7D 40013 (exec) 0x01
52
MODBUSINFORMATION
Time step
Master's action BMS-350 action Registers
26 Polls command status register. Sees OK (0x01). Proceeds to next step.
40010 (status) 0x01 40011 (cmd) 0x04 40012 (param) 0x7D 40013 (exec) 0x01
27 Write 0x00 to command exec reg.
40010 (status) 0x01 40011 (cmd) 0x04 40012 (param) 0x7D 40013 (exec) 0x00
28 Sees command exec register with zero value. Returns to idle state.
40010 (status) 0x55 40011 (cmd) 0x04 40012 (param) 0x7D 40013 (exec) 0x00
29 Polls command status register. Sees IDLE (0x55). All done!
40010 (status) 0x55 40011 (cmd) 0x04 40012 (param) 0x7D 40013 (exec) 0x00
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
SW1-2 Modbus address bit 1 “ON” position is “1”, “OFF” is 0
SW1-3 Modbus address bit 2 “ON” position is “1”, “OFF” is 0
SW1-4 Modbus address bit 3 “ON” position is “1”, “OFF” is 0
SW1-5 Modbus address bit 4 “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
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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:
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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
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