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 Option Option Option Ignored

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

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

Modbus*

Enable/

Disable

Peer-To-Peer

Modbus*

Enable/

Disable

Remote

Setpoint

Peer-To-Peer

Modbus*

Enable/

Disable

Remote

Setpoint

Peer-To-Peer

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

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

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

O+,O-

Terminal Number

44,30,

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

R+,R-

BO,BC

LC , O O ,WF,

GP,HL

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-

70,71,

8,27,

2,30

25,30

10,27/

6,79,

80 49

9,51/f

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 The modulation output is held at the Low Fire for the Low Fire Hold time. 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)

- Lead Boiler Start

- Temperature Based Lag Boiler Start

- Modulation % Based Lag Boiler Start

- Lag Boiler Stop

- 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

FIRING RATE

3 2 1 0

(# BOILERS REQURED)

Lead Boiler

Start

Fast

Load

Change

Lag

Slow

Load

Change

Start

Lag

Stop

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

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.

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

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

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.

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

Fresh Air

Supply

Combustion Air

Open/Close (SO)

Damper

Boiler Inlet

Temperature

(BI, BC)

Standby System Pump

Mixing Valve

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

Front Panel

Display Navigation

Press and hold the key to leave the Display Mode and access the Main Menu:

Main Menu

DISPLAY MODE BOILER CONFIG SYSTEM CONFIG

SETUP

SETPOINTS

COMMUNICATION

DIAGNOSTICS

SECURITY

MANUAL MODE

Arrow Keys :

Up / Down

thr oug h Lis t s

ENTER

Sub Menus

DISPLAY MODE

BOILER CONFIG

SYSTEM CONFIG

SETUP

SETPOINTS

COMMUNICATION

DIAGNOSTICS

SYSTEM

SECURITY

MANUAL MODE

Display Mode Displays: Boiler operating status, Display Only, Values Are Not Editable from this display

Configuration and Setup Menus: Sensor, boiler and system options selections

(refer to page 31)

Setpoints Menu: Operational, On, Off, Min & Max Setpoints, Editable Values (refer to page 19)

Communication Menu Modbus and Peer-To-Peer Network Selections (refer to page 27)

Diagnostic Menu: Fault and Low Inlet Temp history, Input & Output Status (refer to page 41)

System Menu: Software revision, parameter code and sensor calibration (refer to page 43)

Security Menu: Supervisor and Factory access (refer to page 45)

Manual Mode: User set Call For Heat and modulation rate. Menu is visible when supervisor password is entered (Refer to page 38)

Sage Boiler Control Instruction Manual Page 18 of 56

Front Panel

Setpoints Menu

Water Temperature

Operational SP

Call For Heat

Relay (CH)

Deg F

185 180 175

Call For Heat Settings

Factory

No.

Setting

Range / Choices Parameter and Description

Operational Setpoint

70 180 60 F to 230 F

Setpoint used in Local Setpoint Mode when not servicing a Domestic Hot Water Priority (DHWP) request

On Point

71 -5 0 F to –99 F

The boiler starts when the water temperature drops ‘On Point’ degrees below the setpoint.

Off Point

72 15 0 F to 99 F

The boiler stops when the water temperature rises ‘Off Point’ degrees above the setpoint.

High Temp Stop

The boiler stops when the boiler outlet water temperature is above the High

73 210 60 F to 230 F

Temperature Stop setpoint. This setpoint is active in every control mode. If the lead boiler’s boiler outlet temperature is above the high temperature stop all boilers are stopped.

*DHWP Setpoint

The Domestic Hot Water Priority (DHWP) Setpoint is active when DHWP Input

74 180 140 F to 230 F

(DP) closes and “DHWP” parameter is set to “yes” and Local SP Mode is selected. When the contact is closed, the boiler outlet is maintained at, or above, the DHW Setpoint.

*WWSD Setpoint

75 60 40 to 90 F

The Warm Weather Shutdown (WWSD) Setpoint used to disable boiler and or system pump operation when enabled by setting the “WWSD” parameter to “WWSD of Boiler”, “WWSD of Sys Pump” or “Both”

76 230 140 F to 230 F

Max SP

The Maximum Operational Setpoint for all possible Local and Remote modes

Min SP

77 140 60 F to 230 F

The Minimum Operational Setpoint is the lower limit for all Local and Remote modes

78 120 110 F to 235 F

Min BIT

Low Boiler Inlet Temperature alarm and event setpoint.

*Min In H2O Temp.

79 130 110 F to 180 F

Minimum Inlet Water Temperature setpoint used as the Mixing Valve inlet temperature setpoint.

*Max H2O Delta T

80 50 20 F to 50 F

Maximum Water Differential (Boiler Outlet minus Boiler Inlet) Temperature setpoint used as the Mixing Valve differential temperature setpoint.

Max Delta T Hold

81 40 20 F to 50 F

Maximum Water Differential (Boiler Outlet minus Boiler Inlet) Temperature used to hold modulation rate at low fire.

* Only visible when parameter enabled on the configuration and setup menus

Off Point On Point

Time

Sage Boiler Control Instruction Manual Page 19 of 56

Installation

Mounting & Wiring Sensors

The Sage Boiler Control (SBC) is mounted in the burner control panel and wired to the burner circuitry at the factory. These installation instructions will explain how the boiler inlet and outlet water temperature sensors are mounted in the boilers supply and return connections and wired to the SBC. Keep a copy of the boiler installation manual on hand to supplement these instructions.

MPC Boiler

1. Mount Boiler Inlet and Outlet Water Temperature Sensors a. Remove one of the ½” immersion temperature sensors from the Sage Boiler Control Parts Carton and

apply thread sealant to the threads between the probe and hex shoulder.

b. Install the sensor in the ½” tapping faci ng upward on the MPC return manifold. Refer to Figure 1. (If

an RWMT positioning plug has already been installed in this tapping, remove it and replace it with the sensor.) Make sure that the hole in the top of the return water mixing tube is aligned with the tapping in the manifold and that the sensor probe slides through this hole without interference. Wrench the sensor until watertight.

c. Remove the other ½” temperature sensor from the Sage Boiler Control Parts Ca rton and apply thread

sealant to the threads between the probe and hex shoulder.

d. Install the sensor in the ½” supply manif old tapping that faces the rear of the boiler. Refer to Figure 1.

Wrench the sensor until watertight.

2. Install Sensor Junction Box in Boiler Jacket a. The temperature sensor wiring can be run to the burner control panel under the boiler jacket, using the

internal wiring chaseway, or it can be run externally, in rigid or flexible conduit. If the sensor wiring will be run externally, proceed immediately to Part 4 of these instructions. If the sensor wiring will be run within the boiler’s internal chaseway, continue to step b. below.

b. If the jacket front, intermediate, and rear top panels have already been installed, remove them (using

the MPC manual’s installation instructions and working in reverse).

c. If the boiler control wiring has already been installed in the rear top panel, remove the two (2) screws

from the rear flange of the panel, slide the panel back, and tilt it upward in order to gain access to the primary internal junction box.

d. Remove the senso r J-box and black snap bushing from the Sage Boiler Control Parts Carton and

install the bushing in the 7/8” hole in the J-box. Mount the sensor J-box (with the snap bushing facing upward) to the inside surface of the right split rear panel using two (2) of the #8 x ½” lg. hex head SMS provided. See Figure 1.

3. Install and Connect Temperature Sensor Wiring (If Using Internal Wiring Chaseway) a. Remove the painted sensor J-box cover (with holes) from the carton. If the blank cover plate is

already mounted on the right rear split panel, remove it. Using flexible conduit and the appropriate conduit connectors (supplied by others), connect the inlet and outlet temperature sensor wiri ng to the two (2) holes in the sensor J-box cover plate. Refer to Figures 1 and 2. The conduit length should be sufficient to allow the cover plate to be installed over the sensor J-box opening in the right rear panel.

b. Install one length of shielded electronic wire cable (supplied by others). To prevent electrical

interference from the internal control/safety circuit wiring harness already installed in the chaseway, use foil-shielded, 3-conductor (22 AWG), UL-listed cable, as a minimum. The cable length should be sufficient to reach from the sensor J-box to the SBC terminals in the burner control panel, following the same path as the internal wiring harness.

c. Pull one end of the shielded cable through the snap bushing on top of the sensor J-box. Trim any

excess length from the sensor wires and connect them to the shielded cable leads in the following manner:

i. Connect one wire from each sensor to the black wire in the shielded cable.

ii. Trim the shielded cable’s silver drain wire, so that it will not come in contact with any metal

surfaces within the J-box. The drain wire is not used at this end of the cable.

Sage Boiler Control Instruction Manual Page 20 of 56

iii. Connect the second wire from the inlet temperature sensor to one of the remaining wires in

the cable. Be sure to note the color of the cable wire to ensure that it is connected to the correct terminal on the SBC in later steps.

iv. Connect the second wire from the outlet temperature sensor to the remaining wire in the

cable. Be sure to note the color of the cable wire to ensure that it is connected to the correct terminal on the SBC in later steps.

d. Mount the sensor J-box cover to the right rear panel using two (2) of the #8 x ½” lg. hex head SMS

provided. See Figure 2. Make sure that all of the exposed wires fit inside of the sensor J-box and that none of them are pinched once the cover plate is installed.

e. Using wire ties, secure the shielded cable to the primary junction box and chaseway channel in the

same manner as the internal wiring harness, as shown in the MPC installation manual.

f. When the cable reaches the end of the chaseway at the front of the boiler, secure it to the vertical

frame rail using the same cable clamps that were installed with the internal wiring harness. Refer to the MPC installation manual for details. It may be necessary to temporarily loosen the screws holding the cable clamps in place, in order to fit the shielded cable through each loop along with the internal wiring harness. If it is necessary to loosen these screws, the jacket front panel will have to be removed (if already installed).

g. The shielded cable should exit the boiler jacket through the unused hole in the side of the front panel.

Using flexible conduit and the appropriate conduit connectors (supplied by others), connect the shielded cable to the burner control panel through one of the panel knockouts n ear the SBC.

h. Connect the wire leads to the appropriate SBC terminals, as shown on the “External Connections”

label on the back of the control. (These terminals are also shown on the “Installation: Terminal Layout” page of this manual). For easier access to the SBC terminals in Power Flame burner control panels, remove the screws at the left and right edges of the top panel and rotate the top panel upward, around the hinge at the top rear of the panel box. (See the Power Flame burner manual for details and

illustration.) i. Connect the black wire and silver drain wire from the cable to the SBC’s “BC” terminal. j. Reinstall any jacket panels that may have been removed.

4. Install and Connect Temperature Sensor Wiring (If Using Electrical Conduit Outside of the Boiler Jacket) a. Using flexible conduit and the appropriate conduit connectors (supplied by others), run the inlet and

outlet temperature sensor wiring to a suitable metal junction box. To prevent electrical interference from other wiring in the burner control panel, connect the sensor wires to foil-shielded, 3-conductor (22 AWG), UL-listed cable, as a minimum. Do not make any other wiring connections inside of this junction box. Trim any excess length from the sensor wires and connect them to the shielded cable leads in the following manner:

i. Connect one wire from each sensor to the black wire in the shielded cable.

ii. Trim the shielded cable’s silver drain wire, so that it will not come in contact with any metal

surfaces within the junction box. The drain wire is not used at this end of the cable.

iii. Connect the second wire from the inlet temperature sensor to one of the remaining wires in

the cable. Be sure to note the color of the cable wire to ensure that it is connected to the correct terminal on the SBC in later steps.

iv. Connect the second wire from the outlet temperature sensor to the remaining wire in the

cable. Be sure to note the color of the cable wire to ensure that it is connected to the correct terminal on the SBC in later steps.

b. Using properly supported conduit and the appropriate connectors (supplied by others), connect the

shielded cable to the burner control panel through one of the panel knockouts n ear the SBC.

c. Connect the wire leads to the appropriate SBC terminals, as shown on the “External Connections”

Connect the black wire and silver drain wire from the cable to the SBC’s “BC” terminal.

Sage Boiler Control Instruction Manual Page 21 of 56

Installation

Mounting & Wiring Sensors (Cont.)

Figure 1: Installation of SBC Components (Part 1)

Sage Boiler Control Instruction Manual Page 22 of 56

Installation

Mounting & Wiring Sensors (Cont.)

Figure 2: Installation of SBC Components (Part 2)

Sage Boiler Control Instruction Manual Page 23 of 56

Installation

Mounting & Wiring Sensors (Cont.)

V9/V11 Boilers

1. Mount Boiler Inlet and Outlet Water Temperature Sensors a. Remove one of the ½” immersion temperature sensors from the Sage Boiler Control Parts Carton and

apply thread sealant to the threads between the probe and hex shoulder.

b. Install the supply sensor in the 3/4” tapping T or J (V9, V11 respectfully) using a ¾” x ½” bushing.

Refer to Figure 3. Wrench the sensor until watertight.

c. Remove the other ½” temperature sensor from the Sage Boiler Control Parts Ca rton and apply thread

sealant to the threads between the probe and hex shoulder.

d. Install the return sensor at the lower rear return tapping, using a short 3” nipple and a 3” x 3” x 3” tee

with the branch of the tee bushed down to ½” (or, use a 3” x 3” x ½” tee, if available). For V9, use tapping C and for V11, use tapping B. Refer to Figure 3. Wrench the sensor until watertight.

2. Install and Connect Temperature Sensor Wiring

Follow the instructions above for the MPC sensor wiring, Step 4 “If Using Electrical Conduit Outside of the Boiler Jacket”.

V11

Figure 3

Sage Boiler Control Instruction Manual Page 24 of 56

Installation

Terminal Layout

Alternate Connection For Outside Air Temperature and

RJ-45

(8 pin)

Remote System Temperature (10k ohm Thermister, 5Vdc)

Label 901 a

Boiler Peer-To-Peer

Communication

Network

RJ-11

(6 pin)

Low Water Cutoff Switch Input

Call For Heat Output

O+ O+

Outside Air Temperature (10k ohm Thermister, 5Vdc)

O-

OR+ R+

Remote System Temperature (10k ohm Thermister, 5Vdc)

R-

RDP

Domestic Hot Water Priority

Local / Remote

Remote On / Off (Enable)

Spare Input (Programmable)

12 Vdc Common

(10k ohm Thermister, 5Vdc) Common

Vac

CA - Low Combustion Air Flow HL - Operating or High Limit GP - Gas Pressure Switch WF - Low Water Flow Switch OO - Burner On/Off Switch V-, V+ - Firing Rate Demand (0-10Vdc) P-, P+ - Firing Rate Demand (0-10 Vdc, PWM)

Vdc

V- V+ P- P+

GP WFHL

Flame Safeguard Alarm

Fuel Valve Energized

Vac

Power Common (-24 Vac)

Power Supply (+24 Vac)

(24 Vac)

(24 V ac)

12 Vdc,

0.5 A max total for LO, VI, BP,

SP and SO

Sage Boiler Control Terminal Arrangement (rear view)

Boil er Outlet Temperature

Boiler Inlet Temperature

12Vdc Common

Spare Output (Programmable)

System Pump Start/Stop

Boiler Pump Start/Stop

Vent Inducer Start/Stop

Alarm Indicator

Mixing Valve Output

(4-20 mAdc)

Remote Firing Rate or

Setpoint Input (0-10 Vdc)

CPRALCS

BC BO

C C

C SO SP BP

VI LO MR MS

CC+

Sage Boiler Control Instruction Manual Page 25 of 56

Installation

External Connections

System Water Temperature Sensor

Mount the sensor in the common header downstream of all boiler connections. Locate the sensor a minimum distance of 10 straight pipe diameters from the from flow disturbing fittings.

Outdoor Air Temperature Sensor

Mount the temperature sensor on an outside wall out of direct sunlight, preferably on a north facing wall. Do not mount sensor near exhaust of any kind, as this may affect readings.

Sage Boiler Control Instruction Manual Page 26 of 56

Installation

External Connections (Continued) Outside Air and Remote System Temperature Sensor RJ45 Connection

All boilers may be connected to the remote system temperature (RST) and the outdoor air temperature (OAT) sensors. Only one of each type sensor is needed for connections with up to eight boilers. The lead boiler is automatically enabled to monitor the sensors. As the boiler lead rotates the sensor monitoring is automatically transferred to the new lead boiler.

Boiler 2

Boiler 1

BO I L E R RUNNING

Connect s t o

Up to 8 Boil ers

Power

BOILER RUNNING

Power

Boiler 2

Alarm

RJ-45

Power

O+ O+

O-

OR+ R+

R-

BO ILER RUNNING

Alarm

Mult i pl e Boil er Connec tion Diag ram

(Us i ng the ex tra O+, O-, R+ & R- term inal s t o dai sy chain

the boi l ers t ogether )

Boiler 1

RJ-45

Power

O+ O+

OO-

R+ R+

RR-

BOILER RUNNING

Alarm

RJ-45

O+ O+

O-

OR+ R+

R-

RJ-45

O+ O+

OO-

R+ R+

RR-

Outsi de Ai r

Temperature

Remote System

Temperature

Outsi de Ai r

Temperature

Remote

System

Temperature

Two Boiler

RJ45 C onnec tion Di agram

(Refer to Note 2)

Notes

1. Used Only For Peer-To-Peer Network

. When using Modbus Network wire Outside Air and Remote System sensor

to only one boiler.

2. Wiring from the Outside Air and Remote System Temperature sensors should use low impedance, shielded, twisted pair wire and go directly to the terminals on any one boiler. Signal wiring should not be run in the same conduit with power wiring. Wire shields may be connected to the common terminal (C) located on the same terminal block with the outside air and remote system temperature connections.

3. The RJ45 sensor cables need to be a straight through type cable that connects each pin of the connector on one end to it’s identical pin on the opposite end. Up to a total of three boilers may be connected using a RJ45 splitter. When connecting more than three boilers, it is recommended, and may be more convenient, to use the extra O+, O, R+ & R- terminals to daisy chain the boilers together (eliminating the need for RJ45 cables and splitters and reducing the loop impedance).

Sage Boiler Control Instruction Manual Page 27 of 56

Installation

Communication

The Peer-To-Peer or Modbus networks allow boiler information, including modulation rate and on/off commands, to be sent via a standard phone cable thus avoiding the cost, time and complexity of wiring multiple signals.

RJ11

Sage Control

Boiler 1 Boiler 2

RJ11

RJ11 Splitter

(Not Inc l uded)

RJ11

Sage ControlSage Control

Boiler 3

RJ11 S plitt er

(Not Inc luded)

Connect s to

Up to 8 Boilers

Or Building

Aut om at i on S ys t em

(BAS) Modbus

Connection

Mu ltiple Boile r

RJ11 Connection Diagram

Sage Control

RJ11

Sage Control

RJ11

Boiler 1 Boiler 2

Two Bo ile r

RJ11 Connection Diagram

When Wiring Modbus Communication to a Building Automation System (BAS)

The Modbus communication connects to the same RJ11 port that is used by the peer-to-pee r communication. Connect one end of the RJ11 cable to the SBC and cut off the other end of the cable to access the individual conductors. The SBC is a 2-wire Modbus communication. Connect the "A" and "B " terminals of a four wire or six wire phone cable (as shown below) to the BAS terminals. The SBC includes two sets of A and B connections, where the A represents the active transmission state of the RS485 transmitter (as opposed to the line idle stat e). You need only to wire to one of the "A" terminals and one of the "B" terminals.

Phone cable signals (4 wire) - connect to pin black or yellow and red or green:

Wire Color Black 1 A Red 2 B Green 3 B Yellow 4 A

Notes

2. Please note that all connections between boilers must be kept as short as possible. The maximum cable length

3. In all cases, the wires should be routed away from any obvious sources of electrical noise or magnetic fields

4. SBC power supply common must be grounded at each boiler to enable network communication.

Slot

Connection

Number

Use standard phone cables (although ones that have all six wires terminated at each end) and splitters to connect each boiler.

between boilers must be kept under 25 feet (average distance between all boilers). (motors, fluorescent lights, contactors, spark generators, etc.). Use a separate conduit and junction box from

the power wiring.

Sage Boiler Control Instruction Manual Page 28 of 56

Installation

Communication (Continued)

The Sage Boiler Control communication selections are found on the Communication Menu. Press and hold the key to leave the Display Mode and access the Main Menu:

Use the keys scroll down to the Communication Menu and push the key:

Communication Menu

No.

91 1 1-247

92 19.2

93 None

94 30

97 1 1 to 8

98 - - 6 - - - 321

Factory

Setting

Peer to

Peer

Range / Choices Parameter and Description

Peer to Peer

Modbus

Protocol

Selects between Peer-To-Peer (multiple boiler Lead/Lag control network) and a Modbus slave communication.

Modbus Address

Each boiler must be given a unique address. Only visible when Protocol equals Modbus.

9.6

19.2

38.4

Odd Even None

1-120

Seconds

Baud Rate

Units are 1000 Bits Per Second (KBPS). Only visible when Protocol equals Modbus.

Parity Only visible when Protocol equals Modbus.

Timeout Only visible when Protocol equals Modbus. Messages Rcvd

Diagnostic tool used to confirm wiring and Modbus master configuration. Only visible when Protocol equals Modbus.

Messages Sent

Diagnostic tool used to confirm wiring and Modbus master configuration. Only visible when Protocol equals Modbus.

Boiler Address

Each boiler must be given a unique address. The boiler address assignment determines the boiler sequencing order. A value of 0 disables the network communications. Only visible when Protocol equals Peer to Peer.

Online Status

Each space can be either the boiler address or a ‘ - ‘ depending on whether there is a boiler of that address on-line. Only visible when Protocol equals Peer to Peer.

Example: - - 6 - - - 321 indicates that boilers 6,3,2 and 1 are online

ENTER

Sage Boiler Control Instruction Manual Page 29 of 56

Installation

Peer-To-Peer Network

The Sage Boiler Control includes a dependable Peer-To-Peer communication network. This network allows multiple boiler modulating lead/lag control and status signals to be transferred between boilers. In order to succe ssful use this network certain requirements must be followed.

Network Relevant & Updated Parameters

When using the Peer-To-Peer network certain “Network Relevant” parameters must be configured the same in all boilers (refer to Appendix B for parameter identification). To facilitate the configuration of these “Network Relevant” parameters, a network update feature has been included. Once communications is established between all boilers in a system, changing to a “Network Relevant” parameter at the keypad of any boiler will update that parameter in all boilers. In addition to the “Network Relevant” parameters, other common parameters are also “Updated” over the network (although it is not necessary for them to be set identically among boilers on the network). If you wish to configure them differently among boilers, you will have to disconnect the boiler from the network while you change them to prevent the other boiler from being changed as well. “Network Relevant” and additional “Updated” parameters are identified in Appendix B, Parameter Summary.

Initially Establishing Peer-to-Peer Communication

A Peer-to-Peer network is established as follows:

1. Assign all boilers a unique Boiler Address between 1 and 8 and set the Protocol to Peer-to-Peer

2. Connect all boilers using a RJ11 ended telephone cable

3. Configured all “Network Relevant” parameters identically on all boilers. Unexpected boiler behavior may result if these parameter values differ among boilers on the network. When “Network Relevant” parameters are iden tical the ‘Param Code’ parameter will be identical on each boiler (refer to page 43 for parameter location).

4. When two or more boilers are properly configured for communication, the controllers “auto detect” each other and shares information.

Re-Establishing Peer-to-Peer Communication After an individual boiler Communication Failure

A Peer-to-Peer network is re-established as follows:

1. Ensure Boiler address is between 1 and 8 and is unique

2. Ensure the Protocol parameter is set to Peer-to-Peer

3. Use the ‘Param Code’ parameter to check that “Network Relevant” parameters are configured identically (refer to page 43 for parameter location).

4. Remove control power from the boiler

5. Connect the boiler to the network using a RJ11 ended telephone cable

6. Apply control power to the boiler

7. The network will “auto detect” the new boiler and assign it a position in the sequence based on the boiler address.

When a boiler is operated as a stand alone boiler, away from the network, it establishes itself as a lead boiler. If this stand alone boiler is simply re-connecting to a network of operating boilers there is a potential that boiler operation will be disrupted as the new boiler becomes lead. This potential is avoided by following the above Re-Establishing procedure.

Sage Boiler Control Instruction Manual Page 30 of 56

Installation

RS485 Modbus Network

The Sage Boiler Control includes a dependable Modbus communication network. This network allows boilers to be controlled and/or monitored by a remote system via a RS485 Modbus communication network. Each Sage Boiler Control is a Modbus slave with the following available boiler information:

Modbus Addresses

Coil Address Description Read/Write coil = 0 coil = 1 Notes

00001 00002 00003 00004 00005 00006 00007 00008 00009 00010 00011 00012 00013 00014 00015 00016 00017 00018 00019 00020 00021 00022 00023 00024 00025 00026 00027 00028 00029 00030 00031

00032 00033 00034 00035 00036 00037 00038 00039 00040 00041 00042

Outdoor Air Reset Enable/Disable Domestic Hot Water Priority (DHWP) Local / Remote Remote On / Off Modbus Command Spare Input (Programmable) Low Water Cutoff Switch Burner On / Off Switch Low Water Flow High and Low Gas Pressure Switches Operating or High Limit Low Combustion Air Flow Fuel Valve Energized Flame Safeguard Alarm Call For Heat (CFH) General Alarm Vent Inducer Boiler Pump System Pump Spare Output (Programmable) State Boiler Disabled State Weather Shutdown State Lockout State Pump Purge State Limit Hold State Purge/Pilot Ign State Low Fire/Ignition State Main Ignition State Low Fire Hold State Boiler Running State Fan Post Purge State Pump Cool Down State Standby Annunciator Low Water Level Annunciator Off Switch Annunciator Low Water Flow Annunciator Fuel Limit Annunciator High Temp Limit Annunciator Low Air Flow Annunciator FSG Lockout Annunciator Outlet Temp Fail Annunciator Inlet Temp Fail Annunciator OA Temp Fail

Disable Enable Disable Enable Local Remote

Off On Off On 2 Off On 2 Off On 2 Off On 2 Off On 2 Off On 2 Off On Off On Off On Off On 4 Off On Off On Off On Off On

Off On 3 Off On 3 Off On 3 Off On 3 Off On 3 Off On 3 Off On 3 Off On 3 Off On 3 Off On 3 Off On 3 Off Off Off Off Off Off Off Off Off Off Off

Off On 1

Off On 3

On On On On On On On On On On On

3 4 4 4 4 4 4 4 4 4 4

Sage Boiler Control Instruction Manual Page 31 of 56

Installation

RS485 Modbus Network Modbus Addresses (continued)

Coil Address Description Read/Write coil = 0 coil = 1 Notes

00043 00044 00045 00046

00047

Modbus Register Address

40001 40002 40003 40004 40005 40006 40007 PCB Temperature Sensor -50 300 F 40008 40009 40010 40011

Notes

1. After a Modus communication failure, while using the Modbus connection to monitor or control ‘Comm Failure’ alarm is not cleared until a successful write to both the Remote On / Off Modbus Command (00004) and Remote Firing Rate or Remote Setpoint (40006) points have been completed, power is cycled or the ‘Protocol’ parameter is changed from Modbus to Peer-to-Peer and back again.

2. The limit string points (00006 - 00011) are only monitored when there is a Call For Heat. Additionally, if one of these items is ‘open’ items down stream are not monitored.

3. The boiler "state" points (00020 - 00032) are mutually exclusive (i.e. only one is asserted at a time). This will reflect the state of the message on the front of the boiler. Refer to page 6 for an explanation of each state.

4. The “Annunciated” points (00033 – 00046) reflect the state of the signals used to control the displayed Alarm Message. Refer to pages 39 and 40 for an explanation of each annunciator point.

5. “General Alarm” point (00015) turns “On” when the boiler is indicating any alarm condition.

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

Annunciator Remote Temp Fail Annunciator Remote In Fail Annunciator Comm Fail Annunciator Low Inlet Temp Annunciator Memory Failure

Description

Boiler Outlet Water Temperature Boiler Inlet Water Temperature Outside Air Temperature Boiler Actual Setpoint Remote System Temperature Remote Firing Rate or Remote Setpoint

Firing Rate Output to Mod Motor Minimum Return Temperature Setpoint

Mixing Valve Output Control Mode

Off Off Off Off Off

Engineering

Read/

Write

-50 300 F

-50 300 F 60 230 F

-50 300 F

0 100 % 110 180 F 0 100 % 1 7

Units for Register

= 0

0 100 or 300 % or F 1

Engineering

Units for Register

= 100

On On On On On

Units

4 4 4 4 4

the boilers, the

Not

Sage Boiler Control Instruction Manual Page 32 of 56

Configuration & Tuning

Boiler Configuration Menu

Boiler operating behavior is adjusted using the configuration & tuning menus. Press and hold the key to leave the Display Mode and access the Main Menu: Use the keys scroll down to the required Menu and push the key:

No.

1 Deg F

Factory

Setting

Range / Choices Parameter and Description

Deg F Deg C

Display Units

Selects how temperature parameter values are displayed.

Boiler Pump

Activates the boiler pump output according to selected function None: No Boiler Pump. On Always: Pump Runs Continuously. Purge: Pump Runs during pump pre/post purge operations and during

call for heat.

Lead On: Pump runs continuously when the boiler is the lead and runs

2 None

None

On Always

Purge

Lead On

during the fan pre-purge, while the boiler is running and during fan post purge when a lag boiler.

Pump Prepurge

Sets length of time the boiler pump will be run prior to closing the “Call for Heat” relay (CH).

3 15

0 to 600

Seconds

Postpurge Delta

4 5

0 to 20

C or F

Sets the temperature above boiler inlet temperature that boiler outlet temperature must be below before turning off the boiler pump during pump post purge (Pump Cooldown State).

5 No 6 Yes 7 -

month / day / year

8 No

Yes

hour : minute

Yes

Mixing Valve

Enables the mixing valve control output and user display.

Inlet Sensor (Return Sensor)

Enables the return temperature display and control logic.

Set Time/Date

Displays and sets the time and date of the boiler’s real time clock.

Fuel Limit

Specifies a Fuel Limit such as high and low fuel gas pressure switches a re connected to input (GP). Enables Fuel Limit Hold and alarm messages.

Spare Input

Sets the function of the Spare Input Terminal (SI): Off: Ignore. Sys Pump Feedback: Input (SI) should be wired to a flow switch inserted in

the flow path of the system pump. Input (SI) indicates the system pump is operating. If output (SO) is set to System Backup Pump, system pump output (SO) is energized and System pump Feedback is de-energized the System Backup Pump output (SO) is energized.

9 Off

Off

Sys Pump

Feedback

Low Fire

Low Fire: When the Fuel Valve Energized input (CS) is not

energized and Input (SI) is energized the modulation rate is set to the “Low Fire” setpoint. When input (SI) is not energized, the modulation rate is set to “Fan Purge” setpoint. When the fuel valve energized input (CS) is

energized input (SI) is ignored. Spare Output Sets the function of the Spare Output Terminal (SO): Off: Never close output (SO). CAD: Combustion Air Damper (CAD) or fresh air damper

Closes SO relay with a call for heat, Opens SO relay 2 minutes after call for heat has been de-activated.

System Pump Feedback indicates the Primary System Pump is not operating.

10 Off

System Pump BU

Off

CAD

Soft Alarm

System Pump BU: Closes when System Pump output is activated but the

Soft Alarm: Alarm indication or warning, closes when any alarm is

active, or a condition is preventing a boiler start, including Off Switch.

ENTER

Sage Boiler Control Instruction Manual Page 33 of 56

Configuration & Tuning

System Configuration Menu

No.

20 Off

21 No

22 140 60 F to 140 F

23 220 150 F to 220 F

24 No

25 No

27 No

Factory

Setting

“Low Water Level”

Range / Choices Parameter and Description

Off

Isolated Demand

Shared Demand

Remote SP

Modbus SP Remote Mod Modbus Mod

Display Only

Control

Yes

16 Text

Characters

DHWP

Enables Domestic Hot Water Priority (DHWP) control feature. When input (DP) is energized DHWP becomes active as selected: Off No DHWP Isolated Demand Boiler that receives the input (DP) drops off the

Peer-To-Peer network and it’s temperature setpoint is adjusted above the DHWP Setpoint. The PID output is based on boiler outlet temperature and setpoint. If Remote SP or Remote System temperature sensors were selected, control is switched to the Boiler Outlet Sensor.

Shared Demand If the lead boiler receives the input (DP) the

temperature setpoint for all boilers on the Peer-ToPeer network is adjusted above the DHWP Setpoint

Remote Control

Sets the remote (Energy Management System) control mode as follows: No: Local setpoint and modulation rate is us ed.

Modbus and remote input (C+,C-) are ignored

Remote SP: Remote Input (C+, C-) is used as the temperature

setpoint. Parameter 22 & 23 may be used to adjust the signal range

Modbus SP: RS485 Modbus (40006) is used as the

temperature setpoint

Remote Mod: Remote Input (C+, C-) is used as the modulation

rate.

Modbus Mod: RS485 Modbus (40006) is used as the modulation

rate.

Remote 1.0 Volt=

Sets the temperature corresponding to input (C+,C-) 1Volts. Voltage below 1V is considered invalid, (failed or incorrect wired sensor).

Remote 9.0 Volt=

Sets the temperature corresponding to input (C+,C-) 9 Volts. Voltage above 9V is considered invalid, (failed or incorrect wired sensor).

Remote Sensor

Enables the Remote System Temperature sensor display and control logic: No Remote Sensor Input (R+,R-) is ignored. Display Only Remote Sensor Input (R+,R-) is used for display only Control Remote Sensor Input (R+,R-) is compared with the

temperature setpoint to establish a modulation rate

System Pump

Enables the System Pump output (SO)

LWC or CAD

Specifies a Low Water Cut-off Switch or Combustion Air Damper (Fresh Air Damper) Open switch is connected to input (LC). Enables Limit Hold and alarm messages. Limit hold display message is described by parameter 28

Alarm Message

Limit Hold and alarm message displayed corresponding to sensor connected to input (LC)

The “ENTER” key and “Up” and “Down” arrow keys are used to change the text Message.

Sage Boiler Control Instruction Manual Page 34 of 56

Configuration & Tuning

Setup Menu

No.

30 Off

31 90

32 10

33 5

34 5

35 20

36 20

37 100

38 1

39 220

Factory Setting

Range / Choices Parameter and Description

Off

WWSD of Boiler

WWSD of Sys Pump

Both

50 to 100

% Maximum

Modulation Rate

0 to 50

% Modulation Rate

60 to 900

Seconds

0 to 900

Seconds

1 to 30

Minutes

1 to 30

Minutes

40 - 100

% Modulation Rate

1 - 10

Degrees/Minute

100 - 240

C or F

WWSD

Specifies Warm Weather Shut-Down (WWSD) control of boiler and/or system pump:

Off: Ignores Warm Weather setpoint WWSD of boiler: When Outside Air Temperature (OAT) is higher than

the WWSD setpoint, inhibits boiler start

WWSD of Sys Pump: When OAT is higher than the WWSD setpoint de-

energize System Pump output (SO)

Both: When OAT is higher than the WWSD setpoint, inhibit

Call for Heat and de-energized system pump output (SO)

LL Start Trigger

Specifies the percent of maximum modulation rate the running boiler(s) must reach before calling upon additional boilers for help.

LL Stop Trigger

Specifies the modulation rate that the running boiler(s) must be below before shutting down a lag boiler

Boiler On Delay

Time Delay after On Point setpoint has been reached before starting the next boiler. Short time delay to prevent nuisance starts due to momentary temperature and modulation rate swings

Boiler Off Delay

Time Delay after the Off Point setpoint before stopping the next boiler. Short time delay to prevent nuisance stops due to momentary temperature and modulation rate swings.

%FR On Delay

Time Delay after the modulation rate is above the LL Start Trigger before starting the next boiler. Long time delay to avoid temperature going below setpoint as a result of a slow process change

%FR Off Delay

Time Delay after the modulation rate is below the LL Stop Trigger before stopping the next boiler. Long time delay to avoid temperature going above setpoint as a result of a slow process change

High Fire Limit

To maximize high efficiency condensing operation, the firing rate is limited to an adjustable value. The Sage Boiler Control will keep the boilers at this firing rate or lower as long as the boilers will handle the load. After the last boiler has started the modulation rate is released up to 100%.

Deg/Min Hold Off

Specifies a temperature rate of change that inhibits the next boiler being started or stopped. If the temperature is increasing faster than this rate of change the next boiler is not started. Also, if the temperature is decreasing faster than this rate of change the next boiler is not stopped.

Cutback Setpoint

Boiler Outlet temperature above the Cutback Setpoint causes the modulation rate to be reduced proportionally to help avoid a high temperature limit lockout. This parameter is significant while the boiler is controlled according to the remote system temperature sensor or remote input (C+,C-) or Modbus (40006) Remote Firing Rate.

Sage Boiler Control Instruction Manual Page 35 of 56

Configuration & Tuning

Setup Menu (Continued)

No.

40 150

41 5

42 Disable

43 168

Factory Setting

Range / Choices Parameter and Description

16 to 420

Seconds

3 to 120

Seconds

Disable

Enable

8-720

Hours

Net Start Dwell

The Net Start Dwell Time Delay specifies the length of time the peer-topeer network will wait for the Main Fuel Valve Energized input (CS) to be energized after a boiler Call for Heat. If the Net Start Dwell time is exceeded before the main fuel valve is open the next boiler Call for Heat is initiated without further delay. This parameter should be longer than the sum of the pump purge and boiler purge times.

Limit Fault Time

The Limit Fault Time Delay specifies the length of time the peer-to-peer network will wait for the boiler limits input (CA) to be energized after a boiler Call for Heat. If the Limit Fault time is exceeded before the limits are energized the next boiler Call for Heat is immediately initiated.

Rotation

Enables the lead boiler role to be rotated through the boilers on the network. When disabled the boiler with the lowest network address is lead.

Rotate after

Specifies number of hours (cumulative) a lead boiler runs before passing the lead to another boiler.

Lead role will be surrendered earlier if the lead boiler is placed into manual mode, is run remotely (mode 6), fails to start, is “blind” (all input sensors failed), or is satisfying a DHWP request.

49 100

50 0

51 0

52 0

53 600

54 0

0 to 100

% Full Scale

0 to 100

% Full Scale

0-100

% Modulation Rate

0 to 100

% Modulation Rate

10 to 1200

Seconds

0 to 600

Seconds

Parameters 44 through 48 are found on the following page

Blower Spd High (Linkage Max. Position)

Percent of (0 - 10 Vdc output [V+,V-]) output that represents a 100% modulation rate. This scaling factor allows the Sage Boiler Control to display 100 % when the linkage is at rated boiler output.

Please Note

The Burner input rate adjustment must be completed before can be set. After maximum boiler firing rate is established, the Sage Controller Firing Rate Display “FR” percentage should be 100%. If boiler rate is established at less than 100% FR, that value should be entered in parameter 49 as blower speed high. This will establish the correct scaling factor and will prevent overfiring of the boiler.

Blower Spd Low (Linkage Min. Position)

Percent (0 - 10 Vdc output (V+,V-) or pulse) output that represents a 0% modulation rate. This scaling factor allows the Sage Boiler Control to display 0 % when the linkage is at minimum boiler output.

Low Fire Spd

Modulation % used for Low Fire Hold and Low Fire Start conditions. Low fire position is established by the linkage adjustment. This parameter may be left at 0%. Fan Purge Speed [Note – Fan Purge Speed used during Low Fire Hold (parameter 53)]. Burners with linkage control purge and light-off rates using the RM7800 and linkage adjustments.

Low Fire Hold

Time modulation rate is held at preset value (Low Fire Spd or Fan Purge Spd depending on the state and configuration of Spare Input) after the Fuel Valve Energized Input (CS) is energized.

Post Purge Time

Time modulation rate is held at Purge % setpoint after the Fuel Valve Energized Input (CS) is de-energized.

this parameter

Sage Boiler Control Instruction Manual Page 36 of 56

Configuration & Tuning

Setup Menu (Continued)

230 210 190 170 150 130 110

90 70

Boiler

Setpoint

Ho t Water Setpoint

Outdoor Air Temperature

-20 100800 204060

Boiler Design

Boiler Set Up

230 210 190 170 150 130 110

90 70

Temperature

Hot Water Setpoint

Outdoor Air Temperature

-20 100800 204060

Outdoor Des ign

Outdoor Set Up

Design

Set Up

Temperature

Max Setpoint

Min Setpoint

Outdoor Reset Graph

Energy used by the hot water heating system can be greatly reduced by adjusting (resetting) the operating temperature setpoint as the outdoor temperature changes. Using this approach, the heat lost from the building is matched by the heat input to the building. The control utilizes a reset curve to set the relationship between outdoor temperature and boiler outlet temperature setpoint. The reset curve is determined from the “Set Up” and the “Design” conditions as shown in the above graph and described by parameters 45, 46, 47 and 48:

No.

Factory Setting

Range / Choices Parameter and Description

Outdoor Sensor

Enables the Outside Air Temperature display and control logic: No Outside Air Input (O+O-) is ignored.

44 No

Display Only

Outdoor Reset

Display Only Do Not

temperature, Display Outside Air Temperature

Outdoor Reset Calculate the temperature setpoint based on outdoor

Calculate setpoint based on outdoor

temperature using a reset curve defined by Outdoor Set Up, Boiler Set Up, Outdoor Design and boiler Design parameters

Outdoor Set Up

45 55 F 40 F to 100 F

The Outdoor Set Up temperature is the outdoor temperature at which the Boiler Set Up temperature is supplied.

Boiler Set Up

46 140 F 140 F to 180 F

The Boiler Set Up Temperature is the starting boiler water temperature of the reset ratio. If the building feels cool during mild outdoor conditions, the Boiler Set Up setting should be increased.

Outdoor Design

47 30 F -20 F to 50 F

The Outdoor Design Temperature is the outdoor temperature at which the Boiler Design temperature is supplied.

Boiler Design

The Boiler Design setting is the water temperature required to satisfy the

48 180 F 150 F to 220 F

building heat loss during the Outdoor Design temperature. If the building feels cool during cold outside conditions, the Boiler Design setting should be increased.

Sage Boiler Control Instruction Manual Page 37 of 56

Configuration & Tuning

Setup Menu (Continued)

Slower Response

Factory Setting

Faster Response

Local PID Factory Setting

Slower Response

No.

55 41 0 to 10000

56 15 0 to 10000

57 0 0 to 10000

58 20 0 to 10000

59 30 0 to 10000

60 0 0 to 10000

Factory Setting

Range / Choices Parameter and Description

PID (I)

PID (P)

61 20 10 5 41 30 15 8 36 34 17 9 30 40 20 10 25 48 24 12

15 80 40 20 12 100 50 25 10 120 60 30

9 140 70 35 8 160 80 40

Typical Sage Boiler Control PID Gain and Integral Settings

Local PID P

Proportional Gain value for boiler outlet temperature sensor control Modes. A larger gain value results in tighter, more active, PID control. Gain is the primary PID modulation rate tuning adjustment and provides the immediate modulation rate response.

Pick a gain based on the desired initial response. The burner modulation rate can oscillate if the Proportional Gain is too large.

Local PID I

Integral gain value for boiler outlet temperature sensor control Modes. A smaller value makes the Integral ramp in less time (i.e., faster). Integral is a secondary PID modulation rate tuning adjustment that ramps the output over time (typically minutes) .

Based on the selected Local PID P, select the corresponding (from above table) Integral value. Repeats per minute between 0.5 and 2.0 are typical. The burner modulation rate can oscillate if the Integral time is too small.

Local PID D

The Derivative gain value for boiler outlet temperature sensor control Modes. A larger Derivative gain value produces a larger PID output contribution proportional to the rate of change of the error (Setpoint – Boiler Outlet Temperature). When set equal to zero it has no effect on the output.

Remote PID P

Proportional Gain value for Remote System Temperature sensor control Modes. Refer to Local PID P for explanation.

Remote PID I

Integral Gain value for Remote System Temperature sensor control Modes. Refer to Local PID I for explanation.

Remote PID D

Derivative Gain value for Remote System Temperature sensor control Modes. Refer to Local PID D for explanation.

Repeats/Minute

Sage Boiler Control Instruction Manual Page 38 of 56

Configuration & Tuning

Setup Menu (Continued)

No.

61 15 0 to 10000

62 40 0 to 10000

63 0 0 to 10000

64 15 0 to 10000

65 40 0 to 10000

66 0 0 to 10000

Factory Setting

Range / Choices Parameter and Description

Mixing Valve P

Proportional Gain value for boiler Inlet temperature sensor control mode. A larger gain value results in tighter, more active, PID control. Gain is the primary PID modulation rate tuning adjustment and provides the immediate mixing valve modulation response.

Pick a gain based on the desired initial response. The mixing valve can oscillate if the Proportional Gain is too large.

Mixing Valve I

Integral gain value for boiler inlet temperature sensor control mode. A smaller value makes the Integral ramp in less time (i.e., faster). Integral is a secondary PID modulation rate tuning adjustment that ramps the output over time (typically minutes).

Based on the selected Mixing Valve P, select the corresponding (from table on previous page) Integral value. The mixing valve can oscillate if the Integral time is too small.

Mixing Valve D

The Derivative gain value for boiler inlet temperature sensor control mode. A larger Derivative gain value produces a larger PID output contribution proportional to the rate of change of the error (Setpoint – Boiler Inlet Temperature). When set equal to zero it has no effect on the output.

Max Delta T P

Proportional Gain value for boiler differential (boiler outlet minus inlet temperature sensor) temperature control mode. Refer to Local PID P for explanation.

Max Delta T I

Integral Gain value for boiler differential (boiler outlet minus inlet temperature sensor) temperature control mode. Refer to Local PID I for explanation.

Max Delta T D

Derivative Gain Term for boiler differential (boiler outlet minus inlet temperature sensor) temperature control mode. Refer to Local PID D for explanation.

Sage Boiler Control Instruction Manual Page 39 of 56

Configuration & Tuning

Manual Mode Menu

Manual mode allows the boiler modulation rate, boiler call for head output and mixing valve position to be directly positioned by the user. These are valuable tools for trouble shooting and setup.

No.

101 Auto

102 Varies 0 to 100

103 Varies

104 Man

105 Varies 0 to 100

Factory

Setting

Range / Choices Parameter and Description

Boiler Man/Auto

Man

Auto

On,

Off

Man

Auto

Man: Remain in Manual Mode Auto: Return to Boiler Mode specified by parameter/boiler conditions

Activated only when in Supervisor Mode.

Modulation Rate

Sets the modulation rate to be used for boiler when in Manual Mode Activated only when in Supervisor Mode and Boiler Man/Auto = Man.

Boiler On/Off

Sets the boiler start/stop status when in Manual Mode No: Turn off boiler if running, otherwise remain off Yes: Turn on boiler if off, otherwise remain on.

Activated only when in Supervisor Mode and Boiler Man/Auto = Man.

Mixing Valve M/A

Man: Remain in Manual Mode Auto: Return to Control Mode specified by parameter/boiler conditions

Activated only when in Supervisor Mode.

Mixing Valve

Sets the Mixing Valve % Open to be used for valve when in Manual Mode Activated only when in Supervisor Mode and Mixing Valve M/A equals

Man.

Sage Boiler Control Instruction Manual Page 40 of 56

Trouble Shooting

Alarm Messages

Alarm Messages are shown one at a time in priority order. The message closest to the top of this List is displayed first. Following messages are not shown until the higher priority message has cleared. All alarm messag es are also stored in the Fault History.

LCD Display

Alarm Message

Low Water Level

O Flashing Red Alarm Light

Off Switch Turn Burner Switch

Low Water Flow

O Red Alarm Light

Fuel Limit

O Flashing Red

Alarm Light

High Temp Limit

O Flashing Red Alarm Light

Low Air Flow

O Flashing Red Alarm Light

FSG Fault

O Flashing Red Alarm Light

Outlet Temp Fail

O Red Alarm Light

Inlet Temp Fail

O Red Alarm Light

OA Temp Fail

O Red Alarm Light

Remote Temp

Fail

O Red Alarm Light

Recommended

Action

Manually Reset the

Low Water Cutoff

Ensure boiler pump is

running and boiler

water flow is

unobstructed

Manually Reset the

Fuel pressure switch

Manually Reset the

High Temperature

Aquastat

Check combustion air

blower and air

pressure switch

settings and wiring

Manually Reset

Required, Refer to

Flame Safeguard

Manual corrective

actions

Check wiring and

sensor

Check wiring and

sensor

Check wiring and

sensor

Check wiring and

sensor

Explanation

Low Water Cutoff Switch

When this option is configured and a control is installed, the manual reset low water safety relay is preventing the boiler from starting. If terminal (LC) does not receive power and the Call For Heat output (CH) is powered the “Low Water Level” Message is displayed.

Burner Switch is Off

Control switch is in the OFF position and is preventing the boiler from starting. If terminal (OO) does not receive power and the Call For Heat output (CH) is powered the “OFF Switch” Message is displayed.

Low Water Flow Switch

Low water flow is preventing the boiler from starting. If terminal (WF) does not receive power and the Call For Heat output (CH) is powered the “Low Water Flow” Message is displayed.

Low or High Gas Pressure Switch

The low or high gas pressure switch is preventing the boiler from starting. If terminal (GP) does not receive power and the Call For Heat output (CH) is powered the “Fuel Limit” Message is displayed.

High Limit Temperature

The high temperature limit (HL) (and operational temperature limit when provided) aquastat is preventing a boiler start. If terminal (HL) does not receive power and the Call For Heat output (CH) is powered the “High Temp Limit” Message is displayed.

Low Air Flow or Blocked Vent Switch Not Made

The air flow (and blocked vent switch when provided) is preventing a boiler start. If terminal (CA) does not receive power and the Call For Heat output (CH) is powered the “Low Air Flow” Message is displayed.

Flame Safeguard Fault

The Flame Safeguard is preventing a boiler start. If terminal (AL) receives power at any time, the “Flame Failure” Message is displayed.

Boiler Outlet Temperature Sensor Fail

The boiler outlet temperature sensor is not connected or is reading above or below a valid range. When the boiler outlet sensor fails and the Outlet Sensor mode was selected the control will transfer to Lost Sensor Blind Mode

Boiler Inlet Temperature Sensor Fail

The boiler inlet temperature sensor is not connected or is reading above or below a valid range. When the boiler inlet sensor fails the mixing valve output will drive to 0% and low temperature alarm and maximum water differential (boiler outlet minus boiler inlet) temperature hold are disabled.

Outside Air Temperature Sensor Fail

The outside air sensor is configured and is not connected or is reading above or below a valid range. When the outside air sensor fails the warm weather shutdown (WWSD) and outside air reset control logics are disabled.

Remote System Temperature Sensor Fail

The remote system temperature sensor is configured and is not connected or is reading above or below a valid range. If Remote System Temperature Sensor mode was selected the control will transfer to Boiler Outlet Sensor Mode.

Sage Boiler Control Instruction Manual Page 41 of 56

Trouble Shooting

Alarm Messages (continued)

LCD Display

Alarm Message

Remote Input

Fail

O Red Alarm Light

Comm Failure

O Red Alarm Light

Low Inlet Temp

O Red Alarm Light

Memory Failure

O Red Alarm Light

Recommended Action Explanation

Check wiring and

Remote System

Check wiring and

Remote System

Confirm each boiler has

a unique address

Check wiring and

sensor

Check return water

temperature. Consider

system or operational

changes to avoid low

temperature events

Call Factory

Reset all memories in

System menu:

Clr BIT History

Clr Alarm Hist

Clr Run Time Cnt

Clr Cycle Cnt

Factory Defaults

(Factory Level

Password is required)

Remote Control Input Fail

The Remote Control Input is configured and is not connected or is above or below a valid range. When the remote control input fails the following control mode changes are taken automatically:

Selected Modes Resulting Control Mode Remote Mod Outlet sensor and Local Setpoint Remote Mod & Remote Sensor Remote Sensor and Local Setpoint Remote SP Outlet Sensor and Local Setpoint Remote SP & Remote Sensor Remote Sensor and Local Setpoint

Communication Failure

The Modbus or Peer-To-Peer network has failed. When the Modbus network fails the following control mode changes are taken automatically:

Selected Modes Resulting Control Mode Modbus Mod Outlet sensor and Local Setpoint Modbus Mod & Remote Sensor Remote Sensor and Local Setpoint Modbus SP Outlet Sensor and Local Setpoint Modbus SP & Remote Sensor Remote Sensor and Local Setpoint

After a Modus communication failure, the ‘Comm Failure’ alarm is not cleared until communication is restored and a successful writes to both the Remote On / Off Modbus Command (00004) and Remote Firing Rate or Remote Setpoint (40006) points have been completed, power is cycled or the protocol parameter is changed to Peer-To-Peer and then back to Modbus.

When a Peer-To-Peer network has failed the boilers begin operation as stand alone boilers using the selected parameters.

After a Peer-To-Peer communication failure the ‘Comm Failure’ alarm is not cleared until communication is restored and the boiler rejoins a network with at least one other boiler, power is cycled or the protocol parameter is changed to Modbus and then back to Peer-To-Peer. Low Boiler Inlet Temperature If the boiler inlet temperature is below the Low boiler inlet temperature setpoint, the “Low Inlet Temp” Message is displayed and the boiler inlet temperature history is stored. See following page for additional information on Low boiler inlet temperature history storage and retrieval.

Memory Failure New software has been installed in the Sage Boiler Control or a power interruption has caused a memory failure. The Call For Heat will be prevented until the condition is cleared.

Sage Boiler Control Instruction Manual Page 42 of 56

Trouble Shooting

Diagnostic Menu

All values shown in Diagnostic Menu are for display only and cannot be adjusted by the operator. Press and hold the key to leave the Display Mode and access the Main Menu:

Use the keys scroll down to the Diagnostic Menu and push the key:

ENTER

Boiler Inlet Temperature History

Display Description

13:31 09/10/06 BOT Sensor Fail

8:45 09/10/06 Low Temp: 130F

8:45 09/10/06 Low for 1:00:02

FAULT HISTORY

The last 10 alarms are stored in memory. Use the arrow keys to scroll through

the alarms. Each alarm is displayed with the time and date it occurred.

BIT HISTORY

The last 10 Low Inlet Temperature Events are stored in memory. Each time the boiler inlet temperature is less than the “Min In H2O Temp.” parameter, a low temperature event is recorded. The BIT History screen automatically toggles between the “lowest temperature for the event” and “Duration Below Setpoint” displays and provides time and date of each event.

SYSTEM

Items provided by this menu are shown on page 43

DHW Priority

Off

Local/Remote

Off

Remote On/Off

Off

DISCRETE INPUTS

These screens provide a convenient way to trouble shoot wiring during the installation phase. Each screen provides the status of a controller input.

These displays show the status of the corresponding Discrete Input

Spare Input

Off

Low Water Cutoff

Off

Burner On / Off

Off

Low Water Flow

Off

Fuel Limit

Off

Oper./High Limit

Off

PLEASE NOTE

These displays provide limit string monitoring status. These inputs are only monitored when there is a Call For Heat. Additionally, if one of these items is ‘open’, items down stream are not monitored.

Low Air Flow

Off

Fuel Energized

Off

These displays show the status of the corresponding Discrete Input

FSG Alarm

Off

Sage Boiler Control Instruction Manual Page 43 of 56

Trouble Shooting

Diagnostic Menu (Continued)

Display Description

Call For Heat

Off

Lockout Indicator

Off

Vent Inducer

Off

Boiler Pump

Off

System Pump

Off

Spare Output

Off

Boiler Outlet

Boiler Inlet

Outside Air

DISCRETE OUTPUTS

These screens provide a convenient way to trouble shoot wiring during the installation phase. Each screen provides the status of a controller output.

These displays show the status of the corresponding Discrete Output

ANALOG INPUTS

These screens provide a convenient way to trouble shoot wiring during the installation phase. Each screen provides the status of a controller analog input.

These displays show the status of the corresponding Analog Input

Remote System

Remote Input

PCB Temperature

Boiler Demand

Mix Valve Demand

ANALOG OUTPUTS

These screens provide a convenient way to trouble shoot wiring during the installation phase. Each screen provides the status of a controller analog Output.

These displays show the status of the corresponding Analog Output

Sage Boiler Control Instruction Manual Page 44 of 56

Trouble Shooting

Diagnostic Menu (Continued) System Menu

Display Description

Software Rev.

PCB Temperature

Clr Alarm Hist

Clr Run Time Cnt

Clr Cycle Cnt

Factory Defaults

S 3.24

70 F

Clr BIT Hist

No Action

Actual RST

32 F

Actual OAT

-40 F

Actual BOT

32 F

Actual BIT

32 F

Param Code

Software Revision

Displays current Software Revision.

PCB Board Temperature

The operating range for the control is 32 to 140 F.

Clear Boiler Inlet Temperature (BIT) Memory

No Action History remains unchanged Yes Clears low BIT memory

Clear Alarm History Memory

No Action History Remains unchanged Yes Clears alarms memory

Clear Boiler Run Time Hour Accumulator Memory

Boiler Run Time Hours are displayed in Display Mode as “Hours”. No Action Hours Remain unchanged Yes Clears accumulated hours memory

Clear Boiler Start/Stop Cycle Accumulator Memory

Boiler Start/Stop cycles are displayed in Display Mode as “Cycles”. No Action Hours Remain unchanged Yes Clears accumulated cycles memory

Clear User Installed Parameter Memory

No Action Currently set parameter values are unchanged Set Sets all parameters back to their Factory Default values

Temperature Input Fine Calibration

All inputs are factory calibrated. However, it may become necessary to field

calibrate due to measuring errors resulting from long wire lengths or third party sensor use. This is a single point calibration tool. To gain the greatest benefit, it is recommended to calibrate as close as possible to the expected operating temperature and measure the temperature at the sensor location.

Remote System Temperature (RST) Outside Air Temperature (OAT) Boiler Outlet Temperature (BOT) Boiler Inlet Temperature (BIT)

Calibration Procedure:

1. Select sensor that requires field calibration

2. Run boiler to rated condition

3. Enter the Actual RST, OAT, BOT and BIT

4. Display will flash back to the default (Note Calibration number does not remain on screen)

5. Calibration is complete. A one point calibration offset is calculated and applied.

Parameter Code This number represents “Network Relevant” parameters. It can be used to

ensure that these parameters are identical when establishing a Peer-To-Peer network

Sage Boiler Control Instruction Manual Page 45 of 56

Trouble Shooting

Sensor Resistance Chart

Sensor Temperature vs. Resistance

Water Temperature Ohms of Water Temperature Ohms of Water Temperature Ohms of

°C °F Resistance °C °F Resistance °C °F Resistance

-22 -8 110,460 14 58 16,126 51 124 3,453

-21 -6 103,486 16 60 15,313 52 126 3,311

-20 -4 96,999 17 62 14,546 53 128 3,176

-19 -2 90,962 18 64 13,822 73 164 1,565

-18 0 85,340 19 66 13,139 74 166 1,508

-17 2 80,103 20 68 12,493 76 168 1,453

-16 4 75,222 21 70 11,884 77 170 1,401

-14 6 70,670 22 72 11,307 78 172 1,350

-13 8 66,424 23 74 10,762 79 174 1,302

-12 10 62,460 24 76 10,247 80 176 1,256

-11 12 58,759 26 78 9,760 81 178 1,212

-10 14 55,301 27 80 9,298 82 180 1,169

-9 16 52,069 28 82 8,862 83 182 1,129

-8 18 49,047 29 84 8,448 84 184 1,089

-7 20 46,220 30 86 8,056 86 186 1,052

-6 22 43,574 31 88 7,685 87 188 1,016

-4 24 41,097 32 90 7,333 88 190 981.2

-3 26 38,776 33 92 6,999 89 192 947.9

-2 28 36,601 34 94 6,682 90 194 915.9

-1 30 34,562 36 96 6,382 91 196 885.2 0 32 32,650 37 98 6,097 92 198 855.7 1 34 30,856 38 100 5,826 93 200 827.3 2 36 29,171 39 102 5,569 94 202 800.1 3 38 27,590 40 104 5,325 96 204 773.8 4 40 26,104 41 106 5,093 97 206 748.6 6 42 24,707 42 108 4,872 98 208 724.3 7 44 23,394 43 110 4,663 99 210 700.9 8 46 22,159 44 112 4,463 100 212 678.4 9 48 20,997 46 114 4,273 101 214 656.8

10 50 19,903 47 116 4,093 102 216 635.9 11 52 18,873 48 118 3,921 103 218 615.8 12 54 17,902 49 120 3,757 104 220 596.5 13 56 16,988 50 122 3,601

Sage Boiler Control Instruction Manual Page 46 of 56

Trouble Shooting

Security Menu

Passwords

There are three Access Levels in the system; Basic, Supervisor, and Factory.

• At the BASIC Access Level, the user can view many parameters, but is only allowed to edit a small sub-set of the parameters that are visible.

• At the SUPERVISOR Access Level, the user can view and edit most parameters that are visible. Note: not all parameters will be visible at the Supervisor Access Level.

• At the FACTORY Access Level, all relevant internal parameters in the system will be visible and programmable.

The Basic Access Level is the access level at power-up if the system password parameter is not equal to zero. The Supervisor Access Level is the access level at power-up if the system password parameter is equal to zero. If the system password is non-zero, the Supervisor Access Level may be reached by entering the correct password in the Enter Password parameter.

The Factory Access Level can be reached by entering the factory password in the Enter Password parameter and holding the Enter key for at least two seconds when accepting the value entered Level parameter menu when the system has entered the Factory Access Level. Note that the Access Level parameters value will indicate "Supervisor".

To exit either of the privileged access levels (Factory and Supervisor), change the value of the Access Level parameter from "Supervisor" to "Basic". Also, if no key is pressed for ~ 1 hour, the access level will automatically revert to Basic.

No.

0 to 9999

Factory

Setting

Factory

Password

is 86

Range / Choices Parameter and Description

Access Level

Basic

Supervisor

0 to 9999

Basic: Select Basic Level Access to parameters/variables Supervisor: Select Password Level Access to parameters/variables

Enter Password

Allows user to enter password to gain access to both Supervisor Access and Factory Access Levels.

Set Password

Holds the user-defined password for the boiler. A password = 0 means no password protection. Access Level will default to Supervisor Level at power-up.

. The display will jump to the Access

Sage Boiler Control Instruction Manual Page 47 of 56

Specifications

General

Mechanical: Panel Assembly: 8 inches wide x 6 inches tall Message Display: 2 x 16 Character, 8.06 mm characters

Environmental: Operating Temp: 32 to 140 F (0 to 60 C) Storage Temp: -20 to 150 F (-28 to 65 C) Humidity Limits: 15 to 95% (non-condensing) Front Panel: NEMA 1 Electrical: Power Supply: 24Vac

Note: All 24Vac Inputs must be connected to the same phase as (PR) Internal Power Consumption: 8 VA max, 24Vac (+/- 15%), and 6 VA max, 12Vac 0.5A for LO, VI, BP, SP and SO

Discrete Inputs:

Terminal Description

DP Domestic Hot Water Priority (DHWP) 12 Vdc / 1 mA LR Local / Remote 12 Vdc / 1 mA

RO Remote On / Off (Enable) 12 Vdc / 1 mA

SI Spare Input (Programmable) 12 Vdc / 1 mA

LC Low Water Cutoff Switch 24 Vac / 1mA OO Burner On / Off Switch 24 Vac / 1mA WF Low Water Flow 24 Vac / 1mA GP High and Low Gas Pressure Switches 24 Vac / 1mA

HL Operating or High Limit 24 Vac / 1mA CA Low Combustion Air Flow 24 Vac / 1mA CS Fuel Valve Energized 24 Vac / 1mA

AL Flame Safeguard Alarm 24 Vac / 1mA

Discrete Outputs:

Terminal Description

CH Call For Heat (CFH) 24 Vac / 10A

LO Lockout Indicator 12 Vdc / 100mA

VI Spare Output 12 Vdc / 100mA BP Boiler Pump 12 Vdc / 100mA SP System Pump 12 Vdc / 100mA

SO Spare Output (Programmable) 12 Vdc / 100mA

Analog Inputs:

Terminal Description Rating

BO Boiler Outlet Water Temperature 10k Thermister, 5Vdc, 5 mA max load

BI Boiler Inlet Water Temperature 10k Thermister, 5Vdc, 5 mA max load O+

O -

R+ R -

C+ C -

Analog Outputs:

Terminal Description Rating

P+

PV+

V-

MS MR

Outside Air Temperature 10k Thermister, 5Vdc, 5 mA max load Remote System Temperature 10k Thermister, 5Vdc, 5 mA max load

Remote Modulation Rate or Remote Setpoint

Modulation Rate Output to Mod Motor

Mixing Valve Output 4-20mA

0-10 Vdc (~100K ohm impedance)

1Vdc = 0%, 9Vdc = 100%

0 – 100 % Duty Cycle, 0V – Off, ~10V - On

4 mA = 0 % Open, 20 mA = 100% Open

Rating

0 – 10 V, 5 mA max

Sage Boiler Control Instruction Manual Page 48 of 56

Specifications

General (Continued)

Real Time Clock: Battery Backed, 2 yrs without AC Power Communications: Programming - ISP Port Boiler Peer to Peer – RS485, RTU

Time and Date Battery:

The battery is only is removed from the Sage Boiler Control. When new, the battery can power the clock for approximately 2 years with 24 Vac power removed. The clock battery has a shelf life of approximately 6 years (without ac applied). Sage Boiler Control configuration and user data are stored in non-volatile EEPROM. This battery is NOT used to retain this memory.

The battery is located at the back of the Sage Boiler Control for easy replacement.

Component Description

1. Sage Boiler Control Assembly (un-programmed).......................................................................................102106-01

Individual boiler operating and modulation rate control and modulating lead-lag controller. Built to UL and CSA standards.

2. Replacement Fuse Busman GMC-5A

Repair Part Number

used to power the time of day and date clock chip when the 24 Vac power

3. Immersion Temperature Sensor.................................................................................................................101935-01

½” NPT 10K OHM @ 25C, NTC Thermistor Type, Resistance Ratio R0/R50 = 9.07 temperature sensor for measuring water temperature in supply manifold, return manifold or system header.

4. Outdoor Temperature Sensor.................................................................................................................801SOL0012

10K OHM @ 25C, NTC Thermistor Type, Resistance Ratio R0/R50 = 9.07 outdoor ai r temperature sensor with weather proof box and protective sleeve. For use in outdoor reset applications.

5. Wire Harness (Sage to Q7800H) .........................................................................................................101976-01

6. Q7800H Flame Safeguard Sub Base...................................................................................................101182-01

7. Sage Control (programmed).................................................................................................................102436-01

8.. SBC Parts Carton, MPC [includes MPC Sensor J-Box, Snap bushing (for Sensor J-Box) and MPC

Sensor J-Box Cover (with holes)].........................................................................................................101977-01

Sage Boiler Control Instruction Manual Page 49 of 56

Network

Relevant*

Appendix A

Parameter Summary

Parameter Range / Choices

Factory

Setting

Security

Level**

Page

Update Display Units Deg F / Deg C Deg F Basic 31

Yes Boiler Pump None / On Always / Purge / On Lead None Supervisor Update If Purge, set Pump Prepurge 0 to 600 seconds 15 Supervisor Update Postpurge Delta 0 to 20 F 5 Supervisor

- Inlet Sensor Yes / No Yes Supervisor

- Mixing Valve Yes / No No Supervisor Update Set Time/Date Update Fuel Limit Yes / No No Factory Update Spare Input Off / Sys Pump Feedback / Low Fire Off Supervisor Update Spare Output Off / CAD / Sys Pump BU / Soft Alarm Off Supervisor

Yes DHWP Off / Isolated Demand / Shared Demand Off Basic 32 Yes Remote control

- Remote 1 volts = 60 F to150 F 140 Supervisor

- Remote 9 volts = 150 F to 230 F 220 Supervisor

Yes Remote Sensor No / Display Only / Control No

Yes System Pump Yes / No No Update LWC or CAD Yes / No No Update Alarm Message Low Water level

Yes WWSD

Yes LL Start Trigger 50 to100% of Modulation Rate 90

Yes LL Stop Trigger 0 to 50% of Modulation Rate 25

Yes Boiler On Delay 0 to 900 seconds 5

Yes Boiler Off Delay 0 to 900 seconds 5

Yes %FR On Delay 1 to 30 minutes 20 Factory

Yes %FR Off Delay 1 to 30 minutes 20 Factory

Yes High Fire Limit 40 - 100 % Modulation Rate 100 Supervisor

Yes Deg/Min Hold Off 1 - 10 Degrees / Minute 1 Factory

Yes Cutback Setpoint 100 F - 240 F 220 Factory

Yes Net Start Dwell 16 to 420 Seconds 120 Factory 34

Yes Limit Fault Time 3 to 120 Seconds 5 Factory

Yes Rotation Enable / Disable Disable Basic

Yes Rotation After 8 to720 hours 48 Basic

Yes Outdoor Sensor No / Display Only / Outdoor Reset No Basic

Yes Outdoor Set Up 40 F to 100 F 55 Basic

Yes Boiler Set Up 80 F to 180 F 140 Basic

Yes Outdoor Design - 20 F to 50F 30 Basic

Yes Boiler Design 80 F to 220 F 180 Basic

∗ Parameters identified by “Yes” under the “Network Relevant” column must be configured identically on all boilers.

Unexpected boiler behavior may result if these parameter values differ among boilers on the network. Once communications is established between all boilers in a system, changes to parameters identified as “Yes” or “Update” under the “Network Relevant” column at the keypad of any boiler will update that parameter in all boilers.

** To change your current security level refer to page 46 Security Level operations.

Boiler Configuration Menu

System Configuration Menu

Setup Menu

hour : minute month / day / year

No / Remote SP / Modbus SP /

Remote Mod / Modbus Mod

Off / WWSD of Boiler / WWSD of Sys

Pump / Both

Basic

No Supervisor

Supervisor 32 Supervisor 32 Supervisor 32 Supervisor 32

Off Basic 33

Supervisor 33 Supervisor 33 Supervisor 33 Supervisor 33

31 31 31 31 31 31 31 31 31

32 32

33 33 33 33 33

34 34 34 35 35 35 35 35

Sage Boiler Control Instruction Manual Page 50 of 56

Appendix A

Parameter Summary (continued)

Network

Relevant*

Setup Menu (continued)

- Blower Spd High 0 to100 % of full scale 100 Factory

- Blower Spd Low 0 to100 % of full scale 0 Factory

Low Fire Spd 0 to100 % Modulation Rate 0 Factory

Fan Purge Spd 0 to100 % Modulation Rate 100 Factory

Yes

Yes Post Purge Time 0 to 600 sec 0 Factory

Yes Local PID P 0-10000 20 Supervisor 36

Yes Local PID I 0-10000 30 Supervisor

Yes Local PID D 0-10000 0 Supervisor

Yes Remote PID P 0-10000 20

Yes

Yes Mixing Valve P 0-10000 15 Supervisor 37

Yes Mixing Valve I 0-10000 40 Supervisor

Yes Mixing Valve D 0-10000 0 Supervisor

Yes Mixing Delta T P 0-10000 15

Yes Mixing Delta T I 0-10000 40

Yes Mixing Delta T D 0-10000 0

Low Fire Hold 0 to 1200 sec 0 Factory

Remote PID I Remote PID D

Parameter Range / Choices

0-10000 30 0-10000 0

Factory

Setting

Security

Level**

Supervisor 36 Supervisor 36 Supervisor 36

Supervisor 37 Supervisor 37 Supervisor 37

Page

34 34 34 34 34 34

36 36

37 37

Setpoint Menu

Yes Operational Setpoint 60 F to 230 F 180 Basic 19

Yes On point 0 F to – 99 F -5 Basic

Yes Off Point 0 F to 99 F 5 Basic

Yes High Temp Stop 60 F to 230 F 200 Basic

Yes DHWP setpoint 140 F to 230 F 180 Basic

Yes WWSD setpoint 40 F 90 F 70 Basic

Yes Max SP 140 F to 230 F 230 Supervisor

Yes Min SP 60 F to 230 F 140 Supervisor

Yes Min BIT 110 F to 235 F 120 Factory Update Min Inlet H2O Temp 110 F to 180 F 130 Supervisor Update Max H2O Delta T 20F to 50 F 50 Supervisor Update Max Delta T Hold 20F to 50 F 40 Supervisor

Communication Menu

- Protocol Peer to Peer / Modbus

- Modbus Address 1-247 1

- Baud Rate 9.6 / 19.2 / 38.4 19.2

- Parity Odd / Even / None None

- Timeout 1 Second to 120 Seconds 30

- Boiler Address 1 to 8 1 Supervisor

∗ Parameters identified by “Yes” under the “Network Relevant” column must be configured identically on all boilers.

** To change your current security level refer to page 46 Security Level operations.

19 19 19 19 19 19 19 19 19 19 19

Peer to Peer

Supervisor Supervisor 27 Supervisor 27 Supervisor 27 Supervisor 27

Sage Boiler Control Instruction Manual Page 51 of 56

Appendix B

Customer Parameter Worksheet

Parameter Range / Choices Units

Boiler Configuration Menu Display Units Circle one: Deg F Deg C Boiler Pump Circle one: None On Always Purge On Lead

Pump Prepurge Seconds Postpurge Delta F Inlet Sensor Circle one: Yes No Mixing Valve Circle one: Yes No Spare Input Circle one: Off Low Fire Sys Pump Feedback Spare Output Circle one: Off CAD Soft Alarm Sys Pump BU

System Configuration Menu DHWP Circle one: Off Isolated Demand Shared Demand

Remote control Remote 1 volts = F

Remote 9 volts = F Remote Sensor Circle one: No Display Only Control System Pump Circle one: Yes No LWC or CAD Circle one: Yes No Alarm Message

Circle one: No Remote SP Modbus SP Remote Mod Modbus Mod

Setup Menu

WWSD Circle one: Off WWSD of Boiler WWSD of Sys Pump Both LL Start Trigger LL Stop Trigger Boiler On Delay Seconds Boiler Off Delay Seconds High Fire Limit % Rotation Circle one: Enable Disable Rotation After Hours Outdoor Sensor Circle one: No Display Only Outdoor Reset Outdoor Set Up F Boiler Set Up F Outdoor Design F Boiler Design F Local PID P Local PID I Local PID D Remote PID P

Remote PID I Remote PID D

Mixing Valve P Mixing Valve I Mixing Valve D Mixing Delta T P Mixing Delta T I Mixing Delta T D

% %

Sage Boiler Control Instruction Manual Page 52 of 56

Appendix B

Customer Parameter Worksheet (continued)

Parameter Range / Choices Units

Setpoint Menu

Operational Setpoint F On point F Off Point High Temp Stop DHWP setpoint WWSD setpoint Max SP Min SP Min Inlet H2O Temp Max H2O Delta T Max Delta T Hold

Communication Menu

Protocol Circle one: Peer to Peer Modbus Modbus Address Baud Rate Circle one: 9.6 19.2 38.4

Parity Circle one: Odd Even None Timeout Boiler Address

Seconds

F F F F F F F F F

Sage Boiler Control Instruction Manual Page 53 of 56

SERVICE RECORD

DATE SERVICE PERFORMED

Sage Boiler Control Instruction Manual Page 54 of 56

THIS PAGE LEFT BLANK INTENTIONALLY

Sage Boiler Control Instruction Manual Page 55 of 56

Sage Boiler Control Instruction Manual Page 56 of 56

Burnham Sage Boiler Control Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Instruction Manual

Quick Reference

Overview

Description

Description

Features

Product Features

Installation

Installation

Installation

Installation

Mounting & Wiring Sensors (Cont.)

Installation

Installation

Notes

Coil Address Description Read/Write coil = 0 coil = 1 Notes

Disable Enable Disable Enable Local Remote

Coil Address Description Read/Write coil = 0 coil = 1 Notes

00047

40001 40002 40003 40004 40005 40006 40007 PCB Temperature Sensor -50 300 F 40008 40009 40010 40011

Notes

Description

Read/

Write

0 100 or 300 % or F 1

= 100

Units