Burner Management Systems (BMS)

A burner management system (BMS) is the safety backbone of every fired boiler, heater and dryer. It controls purge, ignition, flame proving and shutdown, and it must work correctly every time. Complete Controls Services, LLC (CCS) designs, programs, troubleshoots and upgrades burner management systems for industrial boilers and burners. Founded in 2017 by technicians, CCS combines hands-on burner experience with controls engineering, serving customers from our base in Blair, Nebraska, across the Midwest and the United States.

Our Burner Management Services

BMS Design

We design burner management systems around your burner, fuel train and applicable industry standards. That includes the sequence of operation, interlocks, permissives, flame detection and the operator interface.

PLC-Based BMS Programming

Many facilities are moving from standalone relay or legacy flame safeguard logic to PLC-based burner management. CCS programs BMS logic on industrial PLC platforms and builds clear HMI screens so operators can see permissives, first-out alarms and burner status at a glance. All logic is programmed to meet your specific application and required industry standards as applicable.

Flame Safeguard Upgrades

Obsolete flame safeguards and scanners can be hard to support and harder to troubleshoot. We replace aging flame safeguard controls and integrate the new equipment with your existing combustion controls and plant systems.

Troubleshooting and Service

Nuisance trips and failed light-offs cost production time. Our technicians troubleshoot interlocks, valve proving, flame scanners, limit switches and wiring to find the actual cause and correct it.

Commissioning and Startup

CCS has performed initial commissioning, retrofits and controls upgrades of many different systems. We check out safety devices, verify sequences and support startup through combustion tuning.

Custom BMS Panels

We build custom control panels for burner management, shop tested prior to shipment.

Equipment and Applications

• Industrial and commercial boilers

• Process and thermal fluid heaters

• Dryers

• HRSGs and duct burners

• Burners of many designs and fuels

Platforms

We work with Allen Bradley (Rockwell Automation), Siemens, Schneider, Fanuc, Keyence, Pro-face, C-more, and other PLC and HMI platforms. BMS and combustion data can also be brought into SCADA systems such as Ignition, iFix, Wonderware or FactoryTalk View Site Edition. We are a Certified Ignition integrator.

Our BMS Project Approach

Every BMS project starts with understanding your burner, fuel train and how your operators run the equipment. We review existing drawings, logic and safety devices, then develop a scope that covers what needs to change and what can stay. Logic and screens are built and tested before arriving on site, which shortens the outage. During startup, we walk through each permissive and trip with your team so they understand what the system is doing and why. When the work is done, you receive updated documentation that reflects how the system was actually built, so future troubleshooting starts from accurate information.

Whether you need a single flame safeguard replaced or a complete PLC-based burner management system for multiple burners, CCS sizes the solution to your equipment and budget.

Why Choose CCS as Your BMS Integrator

• Burner experience plus controls skill. Our team's background includes boiler and burner operations, so we understand how the system behaves in the field, not just on paper.

• Concept through completion. Design, programming, panels, installation support, commissioning and tuning from one company.

• Clear, maintainable logic and operator screens your team can understand.

• Cost-effective, practical solutions that improve safety, efficiency and reliability.

• Midwest-based, nationwide service from Blair, NE.

Related CCS Services

• Boiler Controls Upgrades: Retrofits for obsolete combustion, drum level and feedwater controls, including O2 trim and parallel positioning.

• PLC Programming: New programs, migrations and troubleshooting on Allen Bradley, Siemens and other platforms.

• Custom Control Panels: Panels designed, built and shop tested prior to shipment.

• Combustion Tuning: Analyzer-based burner tuning for efficiency and performance on boilers, dryers, HRSGs and heaters.

Burner Management FAQ

What does a burner management system do?

A BMS manages the safe startup, operation and shutdown of a burner: purge, pilot and main flame ignition, flame supervision and safety shutdowns when an interlock or flame failure occurs.

Can you replace an obsolete flame safeguard?

Yes. We upgrade aging flame safeguard controls and integrate the replacement with your existing burner and combustion controls.

Do you program PLC-based burner management?

Yes. We program BMS logic on industrial PLC platforms, starting with Allen Bradley and Siemens, to meet your application and applicable industry standards.

Will you tune the burner after a BMS upgrade?

We recommend it. CCS provides combustion tuning so the burner runs efficiently after the controls work is complete.

Talk to Us About Your Burner Management System

Call Complete Controls Services at (833) CCS-AUTOMATION ((833) 227-2886), Monday–Friday, 7:30 AM–4:30 PM, or reach us through our contact page.