Burner Management Controller (BMS)

User Manual

Smartphone-Controlled BMS

With smartphone-controlled Burner Management System (BMS) technology, operators can manage combustors, oil heater treaters, and flare igniters remotely, eliminating the need to navigate harsh conditions. This technology enhances convenience, efficiency, precision, and safety.

• Convenience: Control systems from a vehicle or remotely via smartphone.
• Efficiency: Instant adjustments reduce downtime and optimize performance.
• Precision: Fine-tune settings with accuracy to ensure optimal operation.
• Safety: Minimize exposure to hazardous conditions.

This technology drives efficiency, precision, and safety, positioning operators as industry leaders.

Table of Contents

1. Introduction
2. Connecting
3. Specifications
4. Installation
5. Configuration
6. Operation
7. Troubleshooting
8. Maintenance
9. Technical Support
10. Maintenance Program</a>
11. Startup Procedure
12. Monitoring Overview
13. Live Monitor Readings
14. Configuring the Oil Heater Treater
15. VPN Configuration

1. Introduction

The Burner Management Controller (ROS BMS) is designed for oilfield applications, including flares, heater treaters, and combustors. It ensures safety, compliance, and efficiency with RoHS-compliant materials, UL-certified NEMA 4X enclosures, and Wi-Fi connectivity for remote monitoring and control.

2. Connecting

Wi-Fi Connection Guide for ROS BMS

This guide explains how to connect a smartphone, tablet, or laptop to the BMS via Wi-Fi to access the control screen.

What You'll Need

• Wi-Fi-capable device (smartphone, tablet, or laptop).
• BMS unit powered on (12V or 24V DC).
• Web browser (e.g., Chrome, Safari, Edge).

Step-by-Step Wi-Fi Connection

1. Turn On the BMS: Ensure the BMS is powered (check for green light).
2. Open Wi-Fi Settings: Navigate to Wi-Fi settings and select the network (e.g., [flame] or [facility name]).
3. Connect to the Network: Enter password 12345678.
4. Open Control Screen: In a browser, type igniter.local.
5. Save for Easy Access: Add igniter.local to your home screen or bookmark it.

Features

• Flame Sensing Options: Supports thermocouples and ionization sensors.
• Secure Connectivity: Ensures safe remote operations.
• Ignition Flexibility: Options include ignition coil, HEI ignition, and glow plug.
• User-Friendly Interface: Single-page monitoring and configuration.

3. Specifications

• Temperature Output Range:
  • 4-20 mA: 4 mA = 0°F, 20 mA = 2000°F
  • 1-5 V: 1 V = 0°F, 5 V = 2000°F
  • Boolean: Pilot on/off (3.3V = on, 0V = off)
• Power Supply: 12V or 24V DC
• Operating Temperature: -4°F to 140°F
• Dimensions: 12in x 12in x 7in
• Weight: 4 lbs

4. Installation

1. Location Selection: Choose a dry, well-ventilated area away from direct sunlight.
2. Mounting: Secure the controller using provided brackets.
3. Wiring:
   • Connect power (12V or 24V DC) to input terminals.
   • Connect temperature sensors with proper insulation.

⚠ Safety Tip: Wear PPE and follow local electrical regulations.

5. Configuration

Power Up

Connect all the wires from the peripherals to the BMS, then turn on the BMS power switch.

Wi-Fi Setup

1. Open device Wi-Fi settings.
2. Connect to the network (e.g., [flame] or [facility name]).
3. Enter password: 12345678.
4. In a browser, go to igniter.local.
5. Save the link for quick access.
6. Select the BMS that you need.
7. Select Options.
8. Monitor BMS.

Sensor & Ignition Settings

• Flame Sensing: Choose thermocouple or ionization.
• Ignition Method:
  • Ignition Coil (heater treaters)
  • HEI Ignition (flares and combustors)
  • Glow Plug (high condensate locations)

Common Pitfall: Ensure device is within 30-50' for Wi-Fi connectivity. Restart both devices if issues arise.

⚠ Change the default Wi-Fi password (12345678) during initial setup to prevent unauthorized access.

6. Operation

What You Can View & Control

All in One Intuitive Display

• Select & Configure BMS.
• Monitor real-time flame detection & temperature data.
• Adjust alarm thresholds & ignition parameters.
• Monitor Combustor Gas Pressure.
  You can configure the gas pressure threshold to automatically activate the system when the preset pressure level is reached.
• Enable secure Internet connectivity for remote operations.

7. Troubleshooting

• No Power: Check power supply connections and voltage.
• Wi-Fi Issues: Verify network name, signal range, and restart devices.
• Flame Detection Failure: Inspect sensor connections and ensure they are unobstructed.
• Alarm Activation: Adjust alarm settings to match operational parameters.

Troubleshooting Wi-Fi Issues

• Can't find network: Ensure BMS is powered on, move closer (within 30-50 feet), and refresh Wi-Fi.
• Password issues: Verify password (12345678) and restart BMS if needed.
• igniter.local doesn't load: Confirm connection to BMS Wi-Fi, try another browser, or contact support.

Tips: Stay within 30 feet of the BMS, change the default password for security, and save this guide.

8. Maintenance

• Regular Inspections: Check wiring and connections for wear or corrosion.
• Software Updates: Upload firmware updates via USB-C by a ROS technician.
• Calibration: Follow UI guidelines for sensor calibration.
• Cleaning: Keep the controller area free of dust.

9. Technical Support

Contact the ROS BMS support team:

• 📞 Phone: 432-227-4106
• 📧 Email: Bphetteplace@reliableoilfieldservices.net
• 🌐 Website: Reliable-oilfield-services.com

10. Maintenance Program

• Weekly: Check UI and monitoring functions.
• Monthly: Analyze performance logs and verify connections.
• Quarterly: Conduct inspections and recalibrations.
• Annually: Schedule expert review for compliance.

11. Startup Procedure

1. Wi-Fi Connectivity: Connect to the network (password: 12345678) and access igniter.local.
2. Flame Sensing & Ignition: Select preferred methods.
3. Emergency Shutdown (ESD): Locate ESD on the UI.
4. Unit Type Selection: Choose Igniter No Feedback, Igniter Feedback, Oil Heater Treater, or Combustor, then press [Use This Unit].

12. Monitoring Overview

The system provides real-time diagnostics, including operational status, flame detection, temperature readings, and ignition feedback. Each value is clearly defined for easy interpretation.

Definitions

• LO, FB: HI:
  • LO | HI: Solenoid OFF | ON
  • LO | HI: Coil bottom V++ | GND
  • LO/HI: Solenoid closed, no gas flow
  • HI/LO: Solenoid open, gas flowing
  • LO/LO: Solenoid not connected
  • HI/HI: Solenoid fault

13. Live Monitor Readings

Timestamp: 2025-02-20 08:25:20 PM UTC

System Status: Oil Heater Treater is Running

Flame Detection

• Spark Electrode Ion: 100% (Fully engaged)
• Flare Flame Rod Ion: 0% (Inactive)
• Pilot Flame Rod Ion: 0% (Inactive)

Temperature Readings

• Flame TC Temp: Ground-short or not connected
• Oil Bath TC Temp: 93°F

Ignition & Gas Valves

• Glow Plug: LO, FB: HI
• Gas Valve 1: LO, FB: HI
• Gas Valve 2: LO, FB: HI
• Gas Valve 3: LO, FB: HI

Additional Diagnostics

• Ignition Tries: 0
• Oil Level: OK
• Flame Detection: N (No flame detected)
• LED Indicators: Red: N | Green: N | Blue: Y
• GPS: Y (Enabled)

⚠ System Alerts: Pilot Electrode may be Defective. Initiating troubleshooting.

14. Configuring the Oil Heater Treater

This section outlines the configuration process for the Oil Heater Treater, allowing users to define ignition parameters, heating settings, and flame detection preferences.

Configuration Steps

1. Ignition Type: Choose Spark, Glow Plug, or HEI.
2. Ignition Frequency: Set interval (1-10 seconds). Example: If set to 1 second, the system will attempt ignition every second.
3. Glow Plug Duration: Set duration in seconds. Example: If set to 6 seconds, the glow plug will stay energized for 6 seconds per cycle.
4. HEI Duration: Set pulse length (tenths of seconds). Example: A setting of 4 corresponds to 0.4 seconds.
5. Exhaust Test: Enable if temperature exceeds 1100°F for shutdown.
6. Pilot Type: Select Thermocouple, Flame Rod, or Electrode Ionization. Example: If "Electrode Ionization" is checked, the system will use this method for flame verification.
7. Oil Heating Target: Set temperature (°F, 3-degree deadband). Example: If set to 132°F, the heater will regulate the oil bath to this temperature.
8. Calibrate Oil Bath: Adjust temperature controller using "- Calibrate Oil Bath TC +" buttons.
9. Apply Settings: Save changes.
10. Emergency Shutdown (ESD): Press ESD for shutdown.

ESD/Run Settings: Press [ESD] to shut down (changes to [Run]). Keep in shutdown mode during configuration.

15. VPN Configuration

When using a VPN, accessing the ROS BMS on a local Wi-Fi network may require specific configurations.

Enable Split Tunneling

Exclude the BMS's local IP (e.g., 192.168.x.x) from VPN traffic in the VPN client settings. This routes local traffic directly while keeping other traffic encrypted.

Temporarily Disable VPN

Pause the VPN, connect to the BMS, then reconnect the VPN. Avoid sensitive operations while the VPN is off.

Configure Static Routes

Add a static route to direct BMS traffic (e.g., 192.168.1.100) to the local gateway, bypassing the VPN. Example (Windows): route add 192.168.1.100 mask 255.255.255.255 192.168.1.1.

Use a Separate Network Interface

Use a device without an active VPN to connect to the BMS.