Burnham Sage Boiler Control Instruction Manual
Sage Boiler Control
(SBC)
Instruction Manual
Contents
Introduction
Quick Reference 2
Overview 4
Product Features
Boiler Sequence 6
Single Boiler Control Mode 9
Multiple Boiler Control Mode 10
EMS Boiler Control Mode 11
Manual Boiler Control Mode 14
Auiliary Device 15
Front Panel
Features 16
Display Mode 17
Menu Navigation 18
Setpoints Menu 19
Installation
Mounting & Wiring Sensors 20
Terminal Layout 25
External Connections 26
Communication 28
Peer-To-Peer Network 30
RS485 Modbus Network 31
Application
The Sage Boiler Control (SBC) has been designed
for commercial hot water boiler applications.
Intent
This instruction manual includes detailed functional,
installation and setup information.
www.burnhamcommercialcastiron.com
Setup & Tuning
Boiler Configuration Menu 33
System Configuration Menu 34
Setup Menu 35
Manual Mode 40
Trouble Shooting
Alarm Messages 41
Diagnostics Menu 43
Sensor Resistance Chart 46
Security Menu 47
Specifications
General 48
Component Description & Repair Part Numbers 49
Appendix
A. Parameter Summary 50
B. Customer Parameter Worksheet 52
Warranty Rear Cover
Sage Boiler Control Front Panel
(Showing Power & Alarm LEDs,
2 Line 16 Character Message Display
and 4 Pushbuttons)
Sage Boiler Control Instruction Manual Page 1 of 56 102121-01R2 - 4/11
Introduction
Quick Reference
CONTROL
MODE
LCD Display
Typical
Application
Water Setpoint
Temperature
Sensor
Setpoint Operator Operator
“On” and “Off”
Point
Outdoor Air
Reset
Domestic Hot
Water Priority
(DHWP)
Warm Weather
Shutdown
(WWSD)
Call For Heat
Call For Heat
Modulation
Rate
Internal Boiler
Control
Lead Boiler
Control
Remote EMS
Control
Manual
Control
Remote
Connections
Local / Remote
Input (LR)
Outlet Sensor
& Local SP
Mode
Remote Sensor
& Local SP Mode
Single Boiler Multiple Boilers
Outlet Sensor &
Remote SP
Mode
Remote Sensor
& Remote SP
Mode
Remote
Control
Mode
Energy Management System (EMS) Boiler Control
Single Boiler
Setpoint Input
Multiple Boilers
Setpoint Input
Modulation
Rate Input
Manual
Mode
Manual
Operation
Boiler Outlet Remote System Boiler Outlet Remote System Ignored Ignored
Input (C+C-) or
Modbus*
Input (C+C-) or
Modbus*
Ignored Ignored
Operator Operator Operator Operator Ignored Ignored
Option Option Ignored Ignored Ignored Ignored
Option Option Ignored Ignored Ignored Ignored
Option Option Option Option Option Ignored
Based on
Setpoints
Based on
Setpoints
Based on
Setpoints
Based on
Setpoints
Input (RO) or
Modbus
Manually Set
Based on
Setpoint
Peer-to-Peer
Connected
Ignored Ignored Ignored Ignored
Based on
Setpoint
With Peer-to-
Peer Connected
Based on
Setpoint
With Peer-to-
Peer Connected
Based on
Setpoint
With Peer-to-
Peer Connected
Ignored Ignored
Ignored Ignored
Input (C+C-)
or Modbus
Ignored
Ignored Ignored Ignored Ignored Ignored By Operator
Ignored Ignored Closed Closed Closed Ignored
Remote On/Off
(Enable)
Input (RO)
Remote Control
Input (C+C-)
Communication
Network
Additional
Information
Enable/
Disable
No No
Peer-To-Peer
or
Modbus*
Enable/
Disable
Peer-To-Peer
or
Modbus*
Enable/
Disable
Remote
Setpoint
Peer-To-Peer
or
Modbus*
Enable/
Disable
Remote
Setpoint
Peer-To-Peer
or
Modbus*
On/Off Ignored
Remote
Modulation
Modbus
Only
Ignored
Modbus Only
Page 9 Page 10 Page 11 Page 12 Page 13 Page 14
* If Modbus is selected the Peer-To-Peer Network can not be used. Modulating Lead/Lag features require the Peer-ToPeer Network.
Sage Boiler Control Instruction Manual Page 2 of 56
Introduction
Quick Reference
Abbreviation List
Abbreviation Description
AL Flame Safeguard Alarm
BIT Boiler Inlet Temperature
BOT Boiler Outlet Temperature
BP Boiler Pump
BV Blocked Vent Switch
C Common Termination Point
CA Low Combustion Air Flow
CH Call For Heat (CFH)
CS Fuel Valve Energized
DH Domestic Hot Water Heating Demand
DP Domestic Hot Water Priority (DHWP)
SBC Sage Boiler Control
EMS Energy Management System
GP High and Low Gas Pressure Switches
HL High Limit Aquastat
HP High Pressure Gas Switch
IN Boiler Inlet Water Temperature
LC Low Water Cutoff Switch
LL Lead Lag
LO Lockout Indicator
LR Local / Remote
M Electric Motor
Mix 3 Way Mixing Valve
OA Outside Air Temperature
OL Operating Limit Aquastat
OO Burner On / Off Switch
OUT Boiler Outlet Water Temperature
RO Remote On / Off
RST Remote System Temperature
SH Space Heating Demand
SI Spare Input (Programmable)
SO Spare Output (Programmable)
SP Setpoint (As found in “Ope rational SP” and “Remote SP”
SP System Pump
VI Vent Inducer
WF Low Water Flow
WWSD Warm Weather Shutdown
Termination Number Identification (Typical):
Description
Mixing Valve
Control, (MR, MS)
Termination
Numbers
Sage Boiler Control Instruction Manual Page 3 of 56
Introduction
Overview
Sage Boiler Control Overview
The Sage Boiler Control (SBC) is a complete boiler monitoring and automation system. The SBC provides advanced
boiler modulation, operating control, diagnostics, multiple boiler lead-lag and auxiliary device control. The SBC provid es
advanced control features in an easy to use package.
Flexible, Field Selectable Control
Control modes, water system, boiler auxiliary and
modulating lead/lag control features are menu selectable
without the need for external programmers, laptops or
down loads. Every boiler is shipped with factory defaults
that make field menu selections unnecessary unless you
are applying additional control features.
Boiler Monitoring and Diagnostic Displays
The SBC’s two line by sixteen character LCD display
may be used for monitoring boiler inlet and outlet,
remote system and outside air temperatures, modulation
rate setpoint and modulating percent and mixing valve
demand percent. Additionally, the display automatically
presents boiler sequence messages, alarms, hold and
lockout messages. A diagnostic menu is included that
provides the last 10 alarm messages and boiler inlet
temperature alarm history. Boiler inlet temperature
alarm history includes time and date, the lowest inlet
temperature reached and the amount of time the water
temperature dropped below the alarm setpoint.
Modulation Rate and On/Off Modes
The SBC may simply control boiler modulation and
on/off output based on the boiler water outlet
temperature and an operator adjusted setpoint.
However, using parameter selections, the SBC allows
the boiler modulation and on/off output to respond to
remote system water and outside air temperatures,
Domestic Hot Water Priority (DHWP) input or Energy
Management System (EMS) modulation rate demand,
remote setpoint or remote start/stop commands.
Parameter selections of remote system water
temperature and remote mode determine the choice of
one of six different control modes.
Advanced Availability
The above control modes are menu selectable options.
However, if a selected sensor fails, the SBC
automatically changes to a control mode that will allow
continued automatic operation of the boiler. For
example, in the event of a remote system temperature
sensor failure, the SBC will automatically switch to boiler
outlet temperature sensor based control.
Outdoor Air Reset
When selected the modulation rate setpoint is
automatically adjusted based on outside air temperature.
Outdoor air “reset” setpoint saves fuel by adjusting the
water temperature of a heating boiler lower as the
outside air temperature increases.
Warm Weather Shutdown (WWSD)
Some boilers are used primarily for heating buildings,
and the boilers can be automatically shutdown when the
outdoor air temperature is warm. When outside air
temperature is above the WWSD setpoint, this function
will prevent the boiler, boiler pump and/or the system
pump from starting.
Domestic Hot Water Priority (DHWP)
Some boilers are used primarily for building space
heating, but also provide heat for the domestic hot water
users. When the outdoor temperature is warm, the
outdoor reset setpoint may drop lower than a desirable
domestic hot water temperature. When enabled and a
DHWP contact input is detected, the hot water setpoint
is adjusted to be greater than a field adjustable DHWP
Setpoint.
Water Side Control Outputs
In order to maximize the life and availability of hot water
systems it may be desirable to automate mixing valves,
boiler pumps, system pumps, and standby system
pumps. The SBC makes this type of automation totally
integrated and cost effective. The control of these
devices is field selectable through simple yes/no menu
selections.
Combustion Air Side Control Outputs
Boiler room Combustion air dampers (fresh air dampers)
and Vent Inducer control outputs are field selectable
options.
Peer-To-Peer Network
The SBC includes state-of-the-art modulating lead-lag
sequencer for up to eight (8) boilers capable of auto
rotation, outdoor reset and peer-to-peer communication.
The peer-peer network is truly “plug and play”.
Communication is activated by simply connecting a
RJ11 telephone line between boilers. The SBC provides
precise boiler coordination by sequencing boilers based
on both remote system water temperature and boiler
modulation rate. For example, the lead boiler can be
configured to start a lag boiler after operating above 90%
modulation rate for longer than an adjustable time. The
boilers are modulated in “unison” (parallel) modulation
rate to ensure even heat distribution
Modbus Communication Interface
A factory configured RS485 Modbus interface is
available
for Energy Management System (EMS) or SCADA
system monitoring and control.
Sage Boiler Control Instruction Manual Page 4 of 56
Introduction
Overview
Standby System Pump
Remote System
System Pump
System
Supply Water
Switch
Domestic Hot
Temperature
Feedback
Water Override
System Pump
Supply
Domestic
Hot Water
System
Modbus RS-485, RJ-11
Local / Remote Switch
High Temperature Limit
Connection
Boiler Outlet TemperatureBoiler Inlet Temperature
Primary
Spare Output
Call For Heat Relay
Fuel Valve Energized
Control
Alarm (Lockout)
Low Fire
Remote On / Off (Enable)
Lockout Indicator
Building Automation
Control
M
Mixing Valve
Boiler Pump
Low Water Flow Switch
Low Water Cutoff Switch
Return Water
Outside Air
Temperature
Sage Boiler Control
FAN
Switch
Air Flow
Combustion
Control
Modutrol Motor
Switch
Damper
Combustion Air
M
Supply
Fresh Air
Boiler On/Off
Boiler
Jacket
Fuel
Fuel Switches
Supply
Sage Boiler Control Instruction Manual Page 5 of 56
Product Features
Boiler Sequence
BOI LER STATE
LCD Display
Pa r a me ter / Notes
Boiler Disable or R em ot e On/Off
Outdoor Air T em p >
Warm Weat her Shut down Set point
Domestic Hot Water Priority
RO
O+,O-
DP
Terminal Number
-
44,30,
75
20,74
Start/ Sto p Seq u en ce St atesPre-Seq u en ce States
Parameter/Note
Boiler Disable
Warm Weather
Shutdown
Locko ut
b &ca aa
Pump Purge
Standby
Purge / Pilot Ignition
Limit Hold
-3/d - - -53 4/d
-
Low Fire / Ignition
Main I gnition
Low Fire Hold
Boiler Running
Pump Cooldown
Fan Post Purge
54/d
Boil e r Enabl e/Disable On
Domestic Hot Water Demand Monitored
Low Fire Hold
Fuel Valv e Energiz ed
Flame Saf eguard Alarm
Sys t em Pum p F eedback
Call For Heat
Recycling Limits
(LC, OO, WF, GP and HL inputs)
Limits
Inputs
Non-Recycling Limits
(Combustion Air Flow (CA Input))
Call For Heat Relay
Lockout Indicator
( M anual R es et R equire d)
Spare Output
Boiler Pump
System Pump
Relay Outputs Inter lo ck Inpu ts
Syst em Pum p Bac k up Pump
Combustion Air Damper
System Alarm
Mix ing Valve Out put
Blower High Speed
Purge %
Modulation
Firing Rat e
Modulation Outputs
Low F ire %
Blower 0 Volts
SI
CS
AL
SI
R+,R-
OR
BO,BC
LC , O O ,WF,
GP,HL
CA
CH
LO
VI
BP
SP
SO
SO
SO
MS,MR
V+,V-,
P+,P-
V+,V-,
P+,P-
V+,V-,
P+,P-
V+,V-,
P+,P-
V+,V-,
P+,P-
9
-
-
9
70,71,
72
8,27,
28
-
-
-
-
2,30
25,30
10
10,27/
e
10
6,79,
80
49
52
-
9,51/f
50
System Pump Feedback Monitored
Call For Heat
Recycling Limits Made
Non-Recycling Limits Made
Call For Heat Relay On
Spare Output On
Boiler Pump On
System Pump On
Starts in response to System Pump Feedback In put SI
Combustion Air Damper Open
Alarm Status is Monitored
Modulate
Notes
a. Boiler Pump is “On” when the Boiler Pump is set to “On Always” or the boiler is lead boiler and Boiler Pump is set to “On Lead”
b. Boiler Pump is "On" when the Boiler Pump is set to "On Always" and WWSD is set to "WWSD of System Pump" or “Off”
c. System Pump is "On" when the System Pump is set to “yes” and WWSD is set to either "WWSD of Boiler" or "Off"
d. Boiler pump is "On" during Prepurge and Post Purge when Boiler Pump is set to "Purge" or boiler is lead & Boiler Pump is set to “On Lead”
e. Combustion Air Damper Spare Output is maintained “On” for 2 minutes after the Call For Heat is removed.
f. Modulation rate is held at purge % when low fire input is not provided.
Sage Boiler Control Instruction Manual Page 6 of 56
Product Features
Boiler Sequence (Continued)
Pre-Sequence States
BOILER
STATE
LCD Display
Boiler
Disabled
Warm
Weather
Shutdown
Lockout Any Mode
Standby
Start/Stop Sequence States
BOILER
STATE
LCD Display
Pump Purge
Limit Hold Any Mode
Purge / Pilot
Ignition
Low Fire /
Ignition
Main Ignition Any Mode
Low Fire
Hold
Boiler
Running
Fan Post
Purge
Pump
Cooldown
CONTROL MODE
LCD Display
Any Mode
(Except for
Remote Control)
Any Mode
(Except for
Manual Mode)
Outlet Sensor &
Local SP Mode
Remote Sensor
& Local SP
Mode
Outlet Sensor &
Remote SP
Mode
Remote Sensor
& Remote SP
Mode
Remote Control
Mode
Manual
Operation Mode
CONTROL MODE
LCD Display
Any Mode
(Except
Manual Mode)
Any Mode
Any Mode
Any Mode The modulation output is held at the Low Fire for the Low Fire Hold time.
Any Mode
Any Mode
Any Mode
Description
Boiler is prevented from starting; Remote On/Off (Enable) (Terminal RO) Input is not
energized.
Boiler is prevented from starting, Warm Weather Shutdown (WWSD) is enabled and
outside air temperature is above the WWSD Setpoint
Boiler is prevented from starting, Flame Safeguard lockout is present. A Flame
Safeguard manual reset is required
Control monitors boiler outlet temperature, a Call For Heat is initiated when boiler
outlet temperature is below the Operational Setpoint
Control monitors Remote System Temperature, a Call For Heat is initiated when
Remote System Temperature is below the Operational Setpoint
Control monitors boiler outlet temperature, a Call For Heat is initiated when boiler
outlet temperature is below the Remote Setpoint Input (Terminal C+,C- or Modbus
Interface)
Control monitors Remote System Temperature, a Call For Heat is initiated when
Remote System Temperature is below the Remote Setpoint Input (terminal C+,C- or
Modbus Interface)
Control monitors Remote On/Off (Enable) input (Terminal RO or Modbus Interface), a
Call For Heat is initiated when input is energized
A Call For Heat is initiated when Manual Mode Menu item Boiler On/Off is set to On
Description
Once a Call For Heat is initiated and Boiler Pump Purge is selected, the pump output
is energized until the Pump Prepurge Time is complete. If the Call For Heat condition
still exists at the end of the Prepurge Time (the temperature of the water at the sensor
may rise with boiler water flowing passed it) the pump will continue to operate and the
Call For Heat Relay is energized
Power is applied to the safety limit string. If any limits does not pass power (is not
energized), the alarm LED and LCD display shows the reason the start sequence is
on Hold. Refer to Trouble shooting section for explanation of individual lockout and
alarm messages
After the limit string passes power, the fan is started, the modulation output is set to
Purge Rate. When the purge period is complete, the flame safeguard sequences on
the ignition transformer and pilot
When the Spare Input Low Fire is selected, modulation output is set to the Low Fire
Speed when the Spare Input is energized.
The main gas valve input is energized and the modulation output is held constant for
an ignition stabilization period
When this Low Fire Hold time is complete, the modulation output is released to
modulate
When water temperature is above setpoint, there is a Flame Safeguard or Limit fault,
the Call For Heat is ended and the modulating output is set to Purge Rate for the Post
Purge Time
When Boiler Pump Purge is selected, the boiler pump remains “on” until the boiler
outlet temperature is less than the Post Purge Delta (default is 5 F) above the Boiler
Inlet Temperature.
Sage Boiler Control Instruction Manual Page 7 of 56
Product Features
Boiler Sequence (Continued)
Multiple Boilers
185
Setpoint
High Fire Limit
(Parameter 37)
1
- Lead Boiler Start
2
- Temperature Based Lag Boiler Start
3
- Modulation % Based Lag Boiler Start
4
- Lag Boiler Stop
5
- Lead Boiler Stop
Notes
- The “Boiler Address” parameter assignment determines the boiler sequencing order.
- The Lead Boiler automatically rotates (when “Rotate” parameter is enabled) based on field adjusted time
- Lead Boiler is the first boiler to turn on and the last boiler to turn off, (First On, Last Off, FOLO).
- Lag Boilers are turned on in order and turned off in reverse order, (First On, Last Off, FOLO).
- Tripped boilers are replaced without waiting for the Boiler On Delay timer. If a tripped boiler becomes available
180
SYSTEM
BOILER
PLANT LOAD
175
TEMPERATURE
100
50
FIRING RATE
0
3
2
1
0
(# BOILERS REQURED)
Lead Boiler
Start
1
Start
st
1
Fast
Load
Change
Lag
2
2
Slow
Load
Change
3
2
Start
nd
Lag
Stop
nd
2
Lag
4 54
Stop
1st Lag
Lead Boiler
Boiler Start and Stop Peer-To-Peer Network Sequence Diagram
(3 boiler system shown, typical for up to 8 boilers)
Water temperature is below the setpoint by more than the “On Point” differential
Water temperature is below the setpoint by more than the “On Point” differential for longer than the adjustable
time delay (“Boiler On Delay” parameter).
The boiler modulation rate has been above the adjustable limit (“LL Start Trigger” parameter) for longer than the
time delay.
The boiler modulation rate has been below the adjustable limit (“LL Stop Trigger” parameter) for long er than the
time delay. Additionally, lag boilers are stopped when water temperature is above the setpoint by more than the
“Off Point” differential for longer than the “Boiler Off Delay” parameter)
The last boiler remains on line until the water temperature is above the “Off Point” setpoint for longer than the
time delay.
(“Rotate After” parameter, default is 168 hours). When rotating, the lead boiler will move to the end of the lag
order and the 1
st
lag boiler will become the lead. The rest of the boilers will then move up in the lag order
accordingly.
it is returned to service.
5
Stop
Sage Boiler Control Instruction Manual Page 8 of 56
Product Features
Single Boiler Control
Display Shows: Outlet Sensor & Local SP Mode
Return
Water
Outside Air
Temperature
(O+, O-)
Boiler
Circulator
Boiler Outlet
Temperature
(BO, BC)
System
Circulator
System
Supply Water
DHW
Override
Switch (DP)
Domestic Hot
Water (DHW)
Supply
Outlet Sensor & Local SP Mode Application Diagram
(Showing Relevant Connections)
Features
Setpoints
The operator selects the setpoint and on and off points
from the LCD display.
Modulation Rate Control
Boiler automatically modulates to maintain the boiler
outlet temperature at setpoint.
Call for Heat
The Call For Heat is determined by the setpoint, on
and off points and boiler outlet temperature.
Options
Outside Air Reset
If enabled, the Outside Air Sensor will automatically
adjusted the setpoint.
Warm Weather Shutdown (WWSD)
If enabled, the WWSD will disable a boiler start when
outside air temperature is above a Warm Weather
Shutdown (WWSD) setpoint.
Domestic Hot Water Priority (DHWP)
If enabled, the DHWP will adjust the setpoint to satisfy
the DHWP setpoint when a DHWP input (DP) is
energized.
Boiler Inlet
Temperature
(BI, BC)
EMS System Hardwired Connections
Lockout Indicator (LO)
Soft Alarm (SO)
Remote On / Off (Enable) (RO)
RJ11, RS-485 Communication
Peer-To-Peer Network
for Modulating Lead/Lag
Or
Modbus Network
for Touch Screen or EMS Monitoring
Selecting This Control Mode
To select Outlet Sensor & Local SP Mode set the following
parameters:
System Configuration Menu:
Remote Control = “No”
Remote System Temperature Sensor = “No”
Remote On / Off (Enable) Input (RO) = Closed
[Jumper (RO) to (C)]
If the Remote On / Off (Enable) (RO) input is opened, the Call
For Heat Relay (CH) is de-energized.
Modbus Network
To establish a Modbus network set the following parameters:
Communication Menu:
Protocol = Modbus
Modbus Address = Give each boiler a unique address.
Baud Rate = Set identical to remote system
Parity = Set identical to remote system
Connect all boilers using a RJ11 ended telephone cable
If the Modbus network is activated the remote system may
monitor and/or control boiler operation. Refer to page 29 for
additional information.
Sage Boiler Control Instruction Manual Page 9 of 56
Product Features
Multiple Boiler Control
Display Shows: Remote Sensor & Local SP Mode
Outside Air
Temperature
(O+, O-)
Remote System
Temperature
(R+,R-)
System
Circulator
Boiler
Circulator
Boiler Outlet
Temperature
(BO, BC)
Boiler
Circulator
Boiler Inlet
Temperature
(BI, BC)
DHW Override
Switch (DP)
Wired to Each
ECM Controller
Boiler
Circulator
RJ11, RS 485
Peer to Peer
Network
Remote System
Temperature
(R+,R-)
Outside Air
Temperature
(O+, O-)
Connects to
Up to Eight
Boilers
Domestic Hot
Water Priority
(DP)
Remote Sensor & Local SP Mode Application Diagram
(Showing relevant connections for 3 boilers, typical for up to 8)
Features
Setpoints
The ope
rator selects the setpoint and on and off points
from the LCD display.
Modulation Rate Control
Boiler automatically modulates to maintain the Remote
System Temperature (RST) at setpoint.
Call for Heat
The Call for Heat is determined by setpoint, on and off
points and RST. If a Peer-To-Peer network is activated, a
Call for Heat is also initiated when the Lead boiler
modulation rate % is above an adjustable High Fire Rate
Limit (parameter 37) for too long a time.
Options
Outside Air Reset
If enabled, the Outside Air Sensor will automatically
adjusted the setpoint.
Warm Weather Shutdown (WWSD)
If enabled, the WWSD will disable a boiler start when
temperature is above a Warm Weather Shutdown (WWSD)
setpoint.
Domestic Hot Water Priority (DHWP)
If enabled, the DHWP will adjust the setpoint to satisfy the
DHWP setpoint when a DHWP contact input (DP) is
closed. When multiple boilers monitor the DHWP input, an
isolated contact is required for each boiler.
Selecting This Control Mode
To select Remote Sensor & Local SP Mode set the
following parameters:
System Configuration Menu:
Remote Control = “No”
Remote System Temperature Sensor = “Control”
Remote On / Off (Enable) Input (RO) = Closed
[Jumper (RO) to (C)]
If the Remote On / Off (Enable) (RO) input is opened, the
Call For Heat Relay (CH) is de-energized.
If the Remote System Temperature Sensor (RST) fails, the
control mode is automatically switched to Outlet Sensor &
Local SP Mode.
Peer-To-Peer Network
To establish a Peer-To-Peer network follow the procedure
provided on page 28.
If the Peer-To-Peer network is activated the Lead boiler
controls modulation rate and Call for Heat for all
networked boilers. Up to 8 networked boilers are fired in
“Unison” (all at the same modulation rate).
Sage Boiler Control Instruction Manual Page 10 of 56
Product Features
Energy Management System (EMS) Boiler Control
Display Shows: Outlet Sensor & Remote SP Mode
Return
Water
Outside Air
Temperature
(O+, O-)
Boiler
Circulator
Boiler Outlet
Temperature
(BO, BC)
System
Circulator
System
Supply Water
DHW
Override
Switch (DP)
Domestic Hot
Water (DHW)
Supply
Outlet Sensor & Remote SP Mode Application Diagram
(Showing relevant connections)
Features
Setpoints
The setpoint is determined by the Remote Input (C+,C-)
or Modbus Input and operator sets the on and off points
from the LCD display.
Modulation Rate Control
Boiler automatically modulates to maintain the boiler
outlet temperature at setpoint.
Call for Heat
The Call For Heat is determined by setpoint, on and off
points and boiler outlet temperature.
Options
Warm Weather Shutdown (WWSD)
If enabled, the WWSD will disable a boiler start when
temperature is above a Warm Weather Shutdown
(WWSD) setpoint.
Outside Air Temperature may be displayed only.
Outside Air Reset and Domestic Hot Water Priority input
(DP) are ignored.
Boiler Inlet
Temperature
(BI, BC)
EMS System Hardwired Connections
Lockout Indicator (LO)
Soft Alarm (SO)
Remote On / Off (Enable) (RO)
Remote Setpoint (C+,C-)
RJ11, RS-485 Communication
Peer-To-Peer Network
for Modulating Lead/La g
Or
Modbus Network
for Touch Screen or EMS Monitoring
Selecting This Control Mode
To select Outlet Sensor & Remote SP Mode set the following
parameters:
System Configuration Menu:
Remote Control = “Remote SP”
Remote System Temperature Sensor = “No”
Local / Remote Input (LR) = Closed
Remote On / Off (Enable) Input (RO) = Closed
[Jumper (RO) to (C)]
When the Local / Remote Input (LR) is open, Remote Input
(C+,C-) is ignored and Outlet Sensor & Local SP Mode is
active.
If the Remote On / Off (Enable) (RO) input is opened, the
Call For Heat Relay (CH) is de-energized.
Modbus Network
To establish a Modbus network set the following parameters:
Communication Menu:
Protocol = Modbus
Modbus Address = Give each boiler a unique address.
Baud Rate = Set identical to remote system
Parity = Set identical to remote system
Connect all boilers using a RJ11 ended telephone cable
If the Modbus network is activated the remote system may
monitor and/or control boiler operation. Refer to page 29 for
additional information.
Sage Boiler Control Instruction Manual Page 11 of 56
Product Features
Energy Management System (EMS) Boiler Control (continued)
Display Shows: Remote Sensor & Remote SP Mode
Return
Water
Outside Air
Temperature
(O+, O-)
Remote System
Temperature
(R+,R-)
System
Circulator
System
Supply Water
Features
Setpoints
The setpoint is determined by the Remote Input (C+,C-)
and operator sets the on and off points from the LCD
display.
Modulation Rate Control
Boiler automatically modulates to maintain the Remote
System Temperature (RST) at setpoint.
Call for Heat
The Call For Heat is determined by setpoint, on and off
points and Remote System Temperature. If a Peer-ToPeer network is activated, a Call for Heat is also initiated
when the Lead boiler modulation rate % is above an
adjustable High Fire Rate Limit (Parameter 37) for too
long a time.
Options
Warm Weather Shutdown (WWSD)
If enabled, the WWSD will disable a boiler start when
temperature is above a Warm Weather Shutdown
(WWSD) setpoint.
Outside Air Reset and Domestic Hot Water Priority input
(DP) are ignored
.
Boiler
Circulator
Boiler Outlet
Temperature
(BO, BC)
Boiler
Circulator
Boiler Inlet
Temperature
(BI, BC)
Remote Sensor & Remote SP Mode Application Diagram
(Showing relevant connections for 3 boilers, typical for up to 8)
Selecting This Control Mode
To select Remote Sensor & Remote SP Mode set the
following parameters:
System Configuration Menu:
Remote Control = “Remote SP”
Remote System Temperature Sensor = “Control”
Local / Remote Input (LR) = Closed [Jumper (LR) to (C)]
Remote On / Off (Enable) Input (RO) = Closed
[Jumper (LR) to (C)]
When the Local / Remote Input (LR) is open, Remote Input
(C+,C-) is ignored and Remote Sensor & Local SP Mode is
active.
If the Remote On / Off (Enable) (RO) input is opened, the
Call For Heat Relay (CH) is de-energized.
Peer-To-Peer Network
To establish a Peer-To-Peer network follow the procedure
provided on page 28.
If the Peer-To-Peer network is activated the Lead boiler
controls modulation rate and Call for Heat for all networked
boilers. Up to 8 networked boilers are fired in “Unison” (all
at the same modulation rate).
Wired to Each
ECM Controller
Boiler
Circulator
EMS System Connections
Lockout Indicator (LO)
Soft Alarm (SO)
Remote On / Off (Enable) (RO)
Remote Setpoint (C+,C-)
Remote System
Temperature
(R+,R-)
Outside Air
Temperature
(O+, O-)
Connects to
Up to Eight
Boilers
RJ11, RS 485
Peer to Peer
Network
Sage Boiler Control Instruction Manual Page 12 of 56
Product Features
Energy Management System (EMS) Boiler Control (continued)
Display Shows: Remote Control Mode
Return
Water
Boiler
Circulator
Boiler Outlet
Temperature
(BO, BC)
System
Circulator
System
Supply Water
Remote Control Mode Application Diagram
(Showing relevant connections)
Features
Modulation Rate Control
The Remote Input (C+,C-) or Modbus input sets
modulation rate. The setpoint is ignored.
Call for Heat
The Call For Heat is determined by Remote On/Off
input (RO) or Modbus input. The on and off points are
ignored. The boiler will turn off if the water
temperature increases past the temperature set on the
Operational Temperature Limit.
Options
Outside Air Reset and Domestic Hot Water Priority
input (DP) and Warm Weather Shutdown are ignored
.
Boiler Inlet
Temperature
(BI, BC)
EMS System Hardwired Connections
Lockout Indicator (LO)
Soft Alarm (SO)
Remote On / Off (Enable) (RO)
Remote Setpoint (C+,C-)
RJ11, RS-485 Communication
Modbus Network
EMS Monitoring and Control
Remote Firing Rate via Modbus
Remote on/off via Modbus
Selecting This Control Mode
To select Remote Control Mode set the following parameters:
System Configuration Menu:
Remote Control = “Remote Mod”
Remote System Temperature Sensor = “Display Only”
Local / Remote Input (LR) = Closed [Jumper (LR) to (C)].
When the Local / Remote Input (LR) is open, Remote Input
(C+,C-) is ignored and Remote Sensor & Local SP Mode is
active.
Modbus Network
To establish a Modbus network set the following parameters:
Communication Menu:
Protocol = Modbus
Modbus Address = Give each boiler a unique address.
Baud Rate = Set identical to remote system
Parity = Set identical to remote system
Connect all boilers using a RJ11 ended telephone cable
If the Modbus network is activated the remote system may
monitor and/or control boiler operation. Refer to page 29 for
additional information.
Sage Boiler Control Instruction Manual Page 13 of 56
Product Features
Manual Boiler Control Mode
Display Shows: Manual Operation Mode and Lost Sensor Blind Mode
Return
Water
Boiler
Circulator
Boiler Outlet
Temperature
(BO, BC)
System
Circulator
System
Supply Water
Boiler Inlet
Temperature
(BI, BC)
EMS System Hardwired Connections
Lockout Indicator (LO)
Soft Alarm (SO)
Remote On / Off (Enable) (RO)
RJ11, RS-485 Communication
Modbus Network
EMS Monitoring
Manual Operation Mode and Lost Sensor Blind Mode Application Diagram
(Showing relevant connections)
MANUAL OPERATION MODE
Features
Modulation Rate Control
The operator sets the modulation rate. The setpoint is
ignored.
Call for Heat
The Call For Heat Relay (CH) is directly controlled by
the operator. The on and off points are ignored. The
boiler will turn off if the water temperature increases
past the temperature set on the High Temperature
LOST SENSOR BLIND MODE
If both Remote System Temperature (RST) and boiler outlet
temperature and the Remote Control input signal (C,-C+) have
failed, the boiler is started and run continuously at the lowest
modulation rate.
If the controller has entered Lost Sensor Blind Mode, the user
may switch the boiler into manual mode or repair, replace or
reconnect required temperature sensors.
Stop parameter.
Options
Outside Air Reset, Warm Weather Shutdown and
Domestic Hot Water Priority are ignored
.
The Spare Output (VI) and Combustion Air Damper
(SO) outputs are energized when the operator starts
the boiler in manual mode.
Selecting This Control Mode
Manual Mode is activated from the Manual Mode
menu when Supervisor password is entered. Simply
set the Boiler Man/Auto parameter to “Man” and adjust
the Modulation Rate and Boiler On/Off menu items as
required. Once activated the green LED flashes. To
leave manual mode set the Boiler Man/Auto parameter
to “Auto”.
Sage Boiler Control Instruction Manual Page 14 of 56
Product Features
Auxiliary Device Control
Return
Water
M
Fresh Air
Supply
Combustion Air
Open/Close (SO)
Damper
Boiler Inlet
Temperature
(BI, BC)
Standby System Pump
Mixing Valve
M
Control (MR, MS)
Boiler Pump
Start/Stop (BP)
Boiler Outlet
Temperature
(BO, BC)
Start/Stop (SO)
System Pump
Start/Stop (SP)
Spare Output (VI)
System Pump
Feedback (SI)
System
Supply Water
Energy Management
System (EMS)
Interface
Modbus RS-485, RJ-11
Connection
Auxiliary Control Application Diagram
(Showing All Options)
Features
Mixing Valve
The primary function of the mixing valve is to protect the
boiler from thermal shock and sustained flue gas
condensation. When configured, the mixing valve output
compares both minimum return water temperature setpoint
to measured return water temperature and boiler
differential temperature setpoint to measured differential
temperature (boiler outlet minus inlet temperature).
If the boiler return water temperature drops below the
minimum inlet water temperature setpoint (“Min In H2O
Temp” parameter) or the differential temperature increases
above the maximum water differential temperature setpoint
(“Max H2O Delta T” parameter) the mixing valve opens to
allow hot boiler outlet water to blend with cold return water.
The valve repositions toward 0% recirculation after return
water increases above setpoint and the differential
temperature reduces below setpoint.
The mixing valve may be controlled manually from the
Manual Mode menu when Supervisor password is entered.
Simply set the Mixing Valve M/A parameter to “Man” and
adjust the Mixing Valve % as required. Once activated the
green LED flashes. To leave manual mode set the Mixing
Valve M/A parameter to “Auto”
Combustion Air Damper and Vent Inducer
When the Relay (CH) is closed, the Combustion Air
Damper (CAD) and Vent Inducer outputs are energized. If
the CAD open position is needed to be proven, a limit
switch may be wired in series with the Low Water Cut-off
Switch input (LC). The alarm Message may be modified to
reflect this change.
Boiler Pump
The Boiler Pump output (BP) may be configured as None,
Always On, Purge or Lead On by setting the Boiler Pump
(parameter 2) (refer to page 31):
Always On Boiler pump runs continuously.
Purge Boiler pump runs during a pump Prepurge
(Pump Prepurge (parameter 3) time before
boiler starts) while the boiler is running and
during a pump cooldown period (pump
cooldown maintains the boiler pump running
until the boiler outlet temperature is within
the Postpurge Delta (parameter 4) degrees
above the boiler inlet temperature).
Lead On: Boiler Pump runs continuously when the
boiler is the lead and during the fan prepurge, while the boiler is running and during
fan post purge when a lag boiler.
The boiler pump sequences are detailed on the boiler
sequence diagram on page 6.
System and Standby System Pump
When configured, the System Pump output (SP) is always
energized except when turned off by the Warm Weather
Shutdown feature. A Standby System Pump output (SO)
may be configured as a backup to the system pump. The
Standby System Pump is started based on the System
Pump Feedback input (SI).
Selecting This Control Mode
These control modes may be selected using the Boiler and
System Configuration menus.
Sage Boiler Control Instruction Manual Page 15 of 56
Front Panel
Features
POWER LED [Steady On Green LED] indicates power is available down
stream of the Sage Boiler Control’s on board fuse.
[Flashing On Green LED] indicates manual mode operation
for boiler modulation
ALARM LED [Steady On Red LED] indicates an alarm is active.
[Flashing On Red LED] indicates a lockout alarm is a c tive
and a manual reset may be required
SCREEN 2 line by 16 character display provides operational, alarm,
sequence status, configuration and diagnostic user in terface
ENTER The ENTER key has no function in display mode. The
ENTER key is used to select menus, menu items and save
edited parameters as follows:
Select Mode (steady text):
Mode or select a menu or menu item
Edit Mode (blinking text):
value. Press MENU to cancel the current editing operation
UP, DOWN Select Mode (steady text):
selected display and move up and down menu items.
Edit Mode (blinking text):
decreases the value of the number being edited, or scrolls
through a list of choices.
MENU Press and hold MENU to change to the Main Menu screen.
When in a sub menu screen, press MENU to move to the
next higher menu. When in Edit Mode (blinking text) Press
MENU to cancel the current editing operation
Press ENTER to change into Edit
Press ENTER to save the current
Press UP, DOWN to change the
Press UP, DOWN to increases or
Sage Boiler Control Instruction Manual Page 16 of 56
Front Panel
Display Mode
All values shown in Display Mode are for display only and can not be adjusted by the operator. The
keys scroll through the Display Mode screens:
Standby
Low Inlet Temp
OUT 189F IN 180F
RST 189F OA 180F
OUT 189F SP 180F
MOD RATE SH 100%
Boiler State
Alarm Message Low Inlet Temp alarm shown, refer to page 41 for
OUT Boiler Outlet Temperature
IN Boiler Inlet Temperature
RST Remote System Temperature
OA Outside Air Temperature
OUT or RST Boiler Outlet or Remote System Temperature
SP Active Setpoint
MOD RATE Modulation Rate
SH Space Heating (active when DH is not)
DH Domestic Hot Water Priority
Standby boiler state shown, refer to the top of page 6 &
7 for explanation of each boiler state
explanation of all possible alarm messages, the
alarm line is left blank when no alarm is active
(visible when ‘Remote Sensor’ = Display Only or
Control)
(visible when ‘Outdoor Sensor’ = Display Only or
Outdoor Reset)
(Remote System when ‘Remote Sensor’ = Control)
(visible when ‘DHWP’ = Yes and DP input is true)
In 180F SP 130F
MIX VALVE 100%
Outlet Sensor &
Local SP Mode
LEAD BOILER 8
Cycles #,###,###
Hours #,###,###
Home Screen
The Boiler State and Alarm Message screen is the ‘Home Screen’ and is reverted to when no key has been selected for
longer than 30 minutes.
Alarm LED
New alarms illuminate the alarm LED and energize an alarm output (SO) (if enabled). If a lockout condition is detected,
the alarm LED will blink and the lockout indication output (LI) is energized. The display Message is cleared and relays
de-energize when the alarm condition is cleared.
In Boiler Inlet Temperature
SP Min In H2O Temp
MIX VALVE Modulation Rate
Control Mode
LEAD BOILER (0 – 8) Lead Boiler, when zero is displayed modulating
CYCLES Number of boiler cycles
HOURS Number of boilers operating hours
Outlet Sensor & Local SP Mode message shown, refer
to page 2 for an overview of each control mode
lead-lag functions are not available
Sage Boiler Control Instruction Manual Page 17 of 56
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