ROS Wi-Fi Burner Management System
User Manual

This quick start is intended for commissioning and functional checkout. Always follow your site safety policies, electrical codes, and equipment OEM requirements.

1. Mount & power: Mount the enclosure securely. Apply 12V or 24V DC per your configuration.
2. Connect to Wi-Fi: Join SSID flame (default) using password 12345678.
3. Open the UI: In a browser, go to igniter.local. Bookmark for repeat access.
4. Select application: Choose your mode (flare, combustor, heater treater, igniter feedback/no-feedback as applicable).
5. Set sensing + ignition: Select flame proving method (thermocouple and/or ionization) and ignition type (spark/HEI/glow).
6. Apply settings: Save configuration in the UI.
7. Run functional test: Confirm ESD, pilot, and main outputs behave as intended; verify flame proving and lockout response.
8. Secure the system: Change SSID/password and restrict access to authorized personnel.

• Qualified personnel: Installation and commissioning should be performed by trained technicians familiar with fired equipment controls.
• Verify I/O: Confirm each output controls the intended device (pilot valve, main valve, ignitor, ESD) before enabling automatic sequences.
• Lockout discipline: Treat lockout events as abnormal operations requiring inspection and corrective action before restart.
• Site policies: Follow your operator's hot work, LOTO, and startup procedures and documentation requirements.

ROS BMS provides local Wi-Fi access for configuration and status viewing, with support for common oilfield fired equipment use cases (flares, combustors, heater treaters). Typical functions include:

• Outputs: ignition device control and valve/solenoid control (pilot/main/aux as configured).
• Flame proving: thermocouple (temperature trend) and/or ionization (flame rod/electrode) depending on configuration.
• Status outputs: analog outputs such as 4–20 mA or 1–5 V for temperature/status signaling (where used).
• Event history: run-time indicators, alarms, and lockout reasons (feature availability depends on deployed firmware/UI).

What "Proving" means

Flame proving is the controller confirming that ignition resulted in a stable flame within a defined time window. If proving fails (or is lost during operation), the controller should close gas valves and enter lockout per your configuration.

What you'll need

• Wi-Fi capable smartphone/tablet/laptop
• Powered BMS (12V or 24V DC)
• Modern browser (Chrome, Safari, Edge)

Step-by-step

1. Power on the BMS and confirm the unit is energized (indicator light behavior varies by build).
2. Open Wi-Fi settings and join the BMS SSID (default: flame).
3. Enter the default password: 12345678.
4. Open a browser and navigate to igniter.local.
5. Bookmark the page for quick return access during commissioning and PM visits.

Common connection issues

• igniter.local not loading: confirm you are connected to the BMS Wi-Fi network (not a site Wi-Fi). Try another browser and disable "Private Relay" features that can affect local resolution.
• Weak signal: move closer or reposition antenna/enclosure per site constraints. Large metal structures can attenuate Wi-Fi.

If your unit is configured differently (I/O count, wiring, or scaling), use the shipping documentation or configuration screen as the source of truth.

Mounting

• Select a location protected from direct impact and excessive vibration.
• Maintain clearance for cable bends, service access, and enclosure door swing.
• Route low-level sensor wiring separately from ignition/high-noise conductors where practical.

Wiring guidelines (field best practices)

• De-energize before wiring: confirm power is OFF and conductors are de-energized.
• Shielding: use twisted pair/shielded cable for thermocouple and ionization runs where feasible.
• Grounding: bond the enclosure to site ground per operator and electrical code requirements.
• Labeling: label each conductor (pilot valve, main valve, ignitor, ESD) to reduce troubleshooting time.

Configuration is performed through the local UI at igniter.local. Typical steps:

1. Select the application: flare, combustor, heater treater, etc.
2. Select ignition type: spark, HEI, or glow plug (as equipped).
3. Select flame sensing: thermocouple and/or ionization (flame rod/electrode).
4. Set timing: ignition frequency and durations appropriate for the application and fuel quality.
5. Set shutdown thresholds: high-temperature shutdown and other interlocks (where used).
6. Apply/save: persist settings before running.

Recommended commissioning checklist

• Confirm all sensors read plausibly (no open/grounded faults).
• Verify valve outputs open/close correctly and return to safe state on ESD/lockout.
• Verify flame proving occurs within the expected window and fails safely when flame is absent.
• Record final settings and provide to the operator for documentation.

During normal operation, the controller sequences ignition and verifies flame presence. The UI can be used to view:

• Current mode (running/stopped/lockout)
• Ignition state and retry counts (where shown)
• Flame sensing status (ionization/thermocouple)
• Temperature readings and shutdown thresholds
• Valve/solenoid state (pilot/main/aux as applicable)

Operator workflow (typical)

1. Verify prerequisites: fuel availability, ESD permissives, and site readiness.
2. Start sequence in the UI (or via configured control input where used).
3. Confirm pilot ignition and flame proving.
4. Confirm main opens only after pilot is proved (application-dependent).
5. Monitor temperatures and status for the first several minutes after startup.

Lockout is a protective state. The controller should close valves and require operator action before restart.

Actual alarm names and behavior may vary by firmware and application profile.

Wi-Fi / UI access

• SSID: flame (default)
• Password: 12345678 (default)
• UI: igniter.local
• Setup page: igniter.local/setup (if enabled)

Common field symptoms

• No power / dark unit: verify supply voltage, fuse, polarity, and terminal torque.
• Won't ignite: verify ignition selection, ignitor wiring, ground bonding, and gas availability.
• Ignites but won't prove: verify sensor selection matches installed sensor; check TC polarity and ionization lead routing.
• Nuisance lockouts: inspect sensor noise sources, grounding, shielding, and ignition timing appropriateness.

Maintenance interval depends on site conditions (dust, H2S, liquids, vibration) and duty cycle. Use this as a baseline and adjust per operator experience.

Firmware updates

Firmware updates (if applicable) should be performed by qualified personnel. Use approved methods (e.g., USB-C service connection) and confirm operation after update.

Many VPNs route all traffic through the tunnel, which can prevent local access to igniter.local. If you must use a VPN:

• Split tunneling: exclude local BMS traffic from the VPN route where policy allows.
• Disable temporarily: pause VPN while connected locally to the BMS network.
• Static route: advanced users may add a local route to the BMS subnet (device and OS dependent).

Do not relax cybersecurity policies without operator approval.

This section provides high-level guidance for typical wiring and configuration patterns. Your exact wiring will depend on the equipment package and site standards.

Waste Gas Flare Stack

• Confirm pilot and main valve control wiring and verify valve fail-safe states.
• Select appropriate ignition type for gas quality and environmental conditions.
• Configure flame verification (thermocouple and/or ionization) and test proving.

Combustor

• Use high-temperature shutdown thresholds appropriate for your combustor package.
• Verify pilot/main sequencing and sensor location to avoid false proving or false trips.
• Confirm any minimum pressure permissives (if used) match installed instrumentation.

Oil Heater Treater

• Confirm oil bath thermocouple wiring and plausible reading at ambient before firing.
• Set temperature cycling thresholds per operator target and safety margins.
• Verify flame proving and lockout behavior during startup and simulated flame loss.

If you need commissioning help, troubleshooting support, or maintenance planning, contact Reliable Oilfield Services.

For faster resolution, include: site location, equipment type (flare/combustor/heater treater), sensor type(s), ignition type, and a description of the failure/lockout event.