Burnham Sage Boiler Control Instruction Manual 1a Controller

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Sage Boiler Control Instruction Manual Page 1 of 56 102121-01R2 - 4/11

Sage Boiler Control

(SBC)

Instruction Manual

www.burnhamcommercialcastiron.com

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

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

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.

Sage Boiler Control Front Panel

(Showing Power & Alarm LEDs,

2 Line 16 Character Message Display

and 4 Pushbuttons)

Sage Boiler Control Instruction Manual Page 2 of 56

Introduction

Quick Reference

CONTROL

MODE

LCD Display

Outlet Sensor

& Local SP

Mode

Remote Sensor

& Local SP Mode

Outlet Sensor &

Remote SP

Mode

Remote Sensor

& Remote SP

Mode

Remote

Control

Mode

Manual

Mode

Energy Management System (EMS) Boiler Control

Typical

Application Single Boiler Multiple Boilers Single Boiler

Setpoint Input Multiple Boilers

Setpoint Input Modulation

Rate Input

Manual

Operation

Water Setpoint

Temperature

Sensor Boiler Outlet Remote System Boiler Outlet Remote System Ignored Ignored

Setpoint Operator Operator

Input (C+C-) or

Modbus* Input (C+C-) or

Modbus* Ignored Ignored

“On” and “Off”

Point Operator Operator Operator Operator Ignored Ignored

Outdoor Air

Reset Option Option Ignored Ignored Ignored Ignored

Domestic Hot

Water Priority

(DHWP) Option Option Ignored Ignored Ignored Ignored

Warm Weather

Shutdown

(WWSD) Option Option Option Option Option Ignored

Call For Heat

Call For Heat Based on

Setpoints Based on

Setpoints Based on

Setpoints Based on

Setpoints Input (RO) or

Modbus Manually Set

Modulation

Rate

Internal Boiler

Control Based on

Setpoint Based on

Setpoint Based on

Setpoint Based on

Setpoint Ignored Ignored

Lead Boiler

Control Peer-to-Peer

Connected With Peer-to-

Peer Connected With Peer-to-

Peer Connected With Peer-to-

Peer Connected Ignored Ignored

Remote EMS

Control Ignored Ignored Ignored Ignored

Input (C+C-)

or Modbus Ignored

Manual

Control Ignored Ignored Ignored Ignored Ignored By Operator

Remote

Connections

Local / Remote

Input (LR) Ignored Ignored Closed Closed Closed Ignored

Remote On/Off

(Enable)

Input (RO)

Enable/

Disable Enable/

Disable Enable/

Disable Enable/

Disable On/Off Ignored

Remote Control

Input (C+C-) No No

Remote

Setpoint Remote

Setpoint Remote

Modulation Ignored

Communication

Network

Peer-To-Peer

or

Modbus*

Peer-To-Peer

or

Modbus*

Peer-To-Peer

or

Modbus*

Peer-To-Peer

or

Modbus*

Modbus

Only Modbus Only

Additional

Information 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-To-

Peer Network.

Sage Boiler Control Instruction Manual Page 3 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 “Operational SP” and “Remote SP”

SP System Pump

VI Vent Inducer

WF Low Water Flow

WWSD Warm Weather Shutdown

Mixing Valve

Control, (MR, MS)

Description

Termination

Numbers

Termination Number Identification (Typical):

Sage Boiler Control Instruction Manual Page 4 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 provides

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 5 of 56

Introduction

Overview

M

M

Domestic Hot

Water Override

Switch

System Pump

Feedback

Spare Output

Standby System Pump

System Pump

Boiler Pump

Mixing Valve

Control

Modutrol Motor

Control

System

Supply Water

Domestic

Hot Water

Supply

Return Water

Outside Air

Temperature

Combustion Air

Damper

Low Water Flow Switch

Low Water Cutoff Switch

Boiler Outlet TemperatureBoiler Inlet Temperature

Remote System

Temperature

High Temperature Limit

Fuel Switches

Combustion

Air Flow

Switch

Remote On / Off (Enable)

Local / Remote Switch

Lockout Indicator

Building Automation

System

Boiler On/Off

Switch

Fuel

Supply

Fresh Air

Supply

FAN

Modbus RS-485, RJ-11

Connection

Call For Heat Relay

Fuel Valve Energized

Alarm (Lockout)

Low Fire

Boiler

Jacket

Primary

Control

Sage Boiler Control

Sage Boiler Control Instruction Manual Page 6 of 56

Product Features

Boiler Sequence

SI

CS

SI

CH

AL

DP

O+,O-

VI

BP

-

-

2,30

SP

25,30

70,71,

72

Outdoor Air Temp >

Warm Weather Shutdown Setpoint

-

Relay Outputs Interlock Inputs

Terminal Number

Parameter/Note

Low Fire Hold

Spare Output

Boiler Pump

System Pump

Modulation Outputs

Call For Heat Relay

Domestic Hot Water Priority

Flame Safeguard Alarm

Parameter / Notes

20,74

Limits

Inputs

9

Call For Heat

Lockout Indicator

(Manual Reset Required) LO

-

44,30,

75

Fuel Valve Energized

Recycling Limits

(LC, OO, WF, GP and HL inputs)

Pump Purge

Main Ignition

Low Fire Hold

Purge / Pilot Ignition

Low Fire / Ignition

Pump Cooldown

Boiler Running

BOILER STATE

LCD Display

System Pump Feedback

9

-

8,27,

28

-

Non-Recycling Limits

(Combustion Air Flow (CA Input))

Blower High Speed

Purge %

Modulation

Low Fire %

Blower 0 Volts

V+,V-,

P+,P - 49

52

-

9,51/f

50

R+,R-

OR

BO,BC

SO

10

System Pump Backup Pump

SO

10,27/

e

Combustion Air Damper

SO

10

System Alarm

LC , OO ,WF,

GP,HL

CA

Mixing Valve Output

MS,MR 6,79,

80

Firing Rate

Boiler Disable

RO

Boiler Disable or Remote On/Off

-

-3/d - - -53 4/d

Spare Output On

Call For Heat Relay On

Recycling Limits Made

Call For Heat

Non-Recycling Limits Made

-

Warm Weather

Shutdown

Standby

Lockout

Limit Hold

Combustion Air Damper Open

V+,V-,

P+,P -

V+,V-,

P+,P -

V+,V-,

P+,P -

V+,V-,

P+,P -

b &ca aa

Fan Post Purge

54/d

Boiler Pump On

Domestic Hot Water Demand Monitored

System Pump On

System Pump Feedback Monitored

Starts in response to System Pump Feedback Input SI

Alarm Status is Monitored

Modulate

Boiler Enable/Disable On

Start/Stop Sequence StatesPre-Sequence States

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 7 of 56

Product Features

Boiler Sequence (Continued)

Pre-Sequence States

BOILER

STATE

LCD Display

CONTROL MODE

LCD Display Description

Boiler

Disabled

Any Mode

(Except for

Remote Control)

Boiler is prevented from starting; Remote On/Off (Enable) (Terminal RO) Input is not

energized.

Warm

Weather

Shutdown

Any Mode

(Except for

Manual Mode)

Boiler is prevented from starting, Warm Weather Shutdown (WWSD) is enabled and

outside air temperature is above the WWSD Setpoint

Lockout Any Mode

Boiler is prevented from starting, Flame Safeguard lockout is present. A Flame

Safeguard manual reset is required

Outlet Sensor &

Local SP Mode Control monitors boiler outlet temperature, a Call For Heat is initiated when boiler

outlet temperature is below the Operational Setpoint

Remote Sensor

& Local SP

Mode

Control monitors Remote System Temperature, a Call For Heat is initiated when

Remote System Temperature is below the Operational Setpoint

Outlet Sensor &

Remote SP

Mode

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)

Remote Sensor

& Remote SP

Mode

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)

Remote Control

Mode Control monitors Remote On/Off (Enable) input (Terminal RO or Modbus Interface), a

Call For Heat is initiated when input is energized

Standby

Manual

Operation Mode A Call For Heat is initiated when Manual Mode Menu item Boiler On/Off is set to On

Start/Stop Sequence States

BOILER

STATE

LCD Display

CONTROL MODE

LCD Display Description

Pump Purge Any Mode

(Except

Manual Mode)

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

Limit Hold Any Mode

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

Purge / Pilot

Ignition Any Mode 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

Low Fire /

Ignition Any Mode When the Spare Input Low Fire is selected, modulation output is set to the Low Fire

Speed when the Spare Input is energized.

Main Ignition Any Mode The main gas valve input is energized and the modulation output is held constant for

an ignition stabilization period

Low Fire

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

Boiler

Running Any Mode When this Low Fire Hold time is complete, the modulation output is released to

modulate

Fan Post

Purge Any Mode 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

Pump

Cooldown Any Mode 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 8 of 56

Product Features

Boiler Sequence (Continued)

Multiple Boilers

175

180

SYSTEM

TEMPERATURE

Setpoint

2

0

50

100

3

185

1

5

4 54

Start

Lead Boiler

Start

1

st

Lag Start

2

nd

Lag Stop

1

st

Lag

0

1

2

3

Stop

2

nd

Lag Stop

Lead Boiler

PLANT LOAD

(# BOILERS REQURED) BOILER

FIRING RATE

2

Fast

Load

Change

Slow

Load

Change

High Fire Limit

(Parameter 37)

Boiler Start and Stop Peer-To-Peer Network Sequence Diagram

(3 boiler system shown, typical for up to 8 boilers)

- Lead Boiler Start

Water temperature is below the setpoint by more than the “On Point” differential

- Temperature Based Lag Boiler Start

Water temperature is below the setpoint by more than the “On Point” differential for longer than the adjustable

time delay (“Boiler On Delay” parameter).

- Modulation % Based Lag Boiler Start

The boiler modulation rate has been above the adjustable limit (“LL Start Trigger” parameter) for longer than the

time delay.

- Lag Boiler Stop

The boiler modulation rate has been below the adjustable limit (“LL Stop Trigger” parameter) for longer 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)

- Lead Boiler Stop

The last boiler remains on line until the water temperature is above the “Off Point” setpoint for longer than the

time delay.

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

(“Rotate After” parameter, default is 168 hours). When rotating, the lead boiler will move to the end of the lag

order and the 1st lag boiler will become the lead. The rest of the boilers will then move up in the lag order

accordingly.

- 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

it is returned to service.

1

3

4

2

5

Sage Boiler Control Instruction Manual Page 9 of 56

Product Features

Single Boiler Control

Display Shows: Outlet Sensor & Local SP Mode

RJ11, RS-485 Communication

Peer-To-Peer Network

for Modulating Lead/Lag

Or

Modbus Network

for Touch Screen or EMS Monitoring

EMS System Hardwired Connections

Lockout Indicator (LO)

Soft Alarm (SO)

Remote On / Off (Enable) (RO)

Boiler Outlet

Temperature

(BO, BC)

Boiler Inlet

Temperature

(BI, BC)

Return

Water

Outside Air

Temperature

(O+, O-) Boiler

Circulator

System

Circulator

DHW

Override

Switch (DP)

System

Supply Water

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.

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 10 of 56

Product Features

Multiple Boiler Control

Display Shows: Remote Sensor & Local SP Mode

Domestic Hot

Water Priority

(DP)

DHW Override

Switch (DP)

Connects to

Up to Eight

Boilers

RJ11, RS 485

Peer to Peer

Network

Remote System

Temperature

(R+,R-)

Outside Air

Temperature

(O+, O-) Boiler

Circulator

System

Circulator

Boiler

Circulator Boiler

Circulator Remote System

Temperature

(R+,R-)

Wired to Each

ECM Controller

Outside Air

Temperature

(O+, O-)

Boiler Outlet

Temperature

(BO, BC)

Boiler Inlet

Temperature

(BI, BC)

Remote Sensor & Local SP Mode Application Diagram

(Showing relevant connections for 3 boilers, typical for up to 8)

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 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 11 of 56

Product Features

Energy Management System (EMS) Boiler Control

Display Shows: Outlet Sensor & Remote SP Mode

RJ11, RS-485 Communication

Peer-To-Peer Network

for Modulating Lead/Lag

Or

Modbus Network

for Touch Screen or EMS Monitoring

EMS System Hardwired Connections

Lockout Indicator (LO)

Soft Alarm (SO)

Remote On / Off (Enable) (RO)

Remote Setpoint (C+,C-)

Boiler Outlet

Temperature

(BO, BC)

Boiler Inlet

Temperature

(BI, BC)

Return

Water

Outside Air

Temperature

(O+, O-) Boiler

Circulator

System

Circulator

DHW

Override

Switch (DP)

System

Supply Water

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.

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 12 of 56

Product Features

Energy Management System (EMS) Boiler Control (continued)

Display Shows: Remote Sensor & Remote SP Mode

System

Supply Water

EMS System Connections

Lockout Indicator (LO)

Soft Alarm (SO)

Remote On / Off (Enable) (RO)

Remote Setpoint (C+,C-)

Return

Water

Connects to

Up to Eight

Boilers

RJ11, RS 485

Peer to Peer

Network

Remote System

Temperature

(R+,R-)

Outside Air

Temperature

(O+, O-) Boiler

Circulator

System

Circulator

Boiler

Circulator Boiler

Circulator Remote System

Temperature

(R+,R-)

Wired to Each

ECM Controller

Outside Air

Temperature

(O+, O-)

Boiler Outlet

Temperature

(BO, BC)

Boiler Inlet

Temperature

(BI, BC)

Remote Sensor & Remote SP Mode Application Diagram

(Showing relevant connections for 3 boilers, typical for up to 8)

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-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

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.

Selecting This Control Mode

To select Remote Sensor & Remote SP Mode set the

following parameters:

System Configuration Menu:

Remote Control = “Remote SP”

Remote System Temperature Sensor = “Control”

Local / Remote Input (LR) = Closed [Jumper (LR) to (C)]

Remote On / Off (Enable) Input (RO) = Closed

[Jumper (LR) to (C)]

When the Local / Remote Input (LR) is open, Remote Input

(C+,C-) is ignored and Remote Sensor & Local SP Mode is

active.

If the Remote On / Off (Enable) (RO) input is opened, the

Call For Heat Relay (CH) is de-energized.

Peer-To-Peer Network

To establish a Peer-To-Peer network follow the procedure

provided on page 28.

If the Peer-To-Peer network is activated the Lead boiler

controls modulation rate and Call for Heat for all networked

boilers. Up to 8 networked boilers are fired in “Unison” (all

at the same modulation rate).

Sage Boiler Control Instruction Manual Page 13 of 56

Product Features

Energy Management System (EMS) Boiler Control (continued)

Display Shows: Remote Control Mode

RJ11, RS-485 Communication

Modbus Network

EMS Monitoring and Control

Remote Firing Rate via Modbus

Remote on/off via Modbus

EMS System Hardwired Connections

Lockout Indicator (LO)

Soft Alarm (SO)

Remote On / Off (Enable) (RO)

Remote Setpoint (C+,C-)

Boiler Outlet

Temperature

(BO, BC)

Boiler Inlet

Temperature

(BI, BC)

Return

Water

Boiler

Circulator

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.

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 14 of 56

Product Features

Manual Boiler Control Mode

Display Shows: Manual Operation Mode and Lost Sensor Blind Mode

RJ11, RS-485 Communication

Modbus Network

EMS Monitoring

EMS System Hardwired Connections

Lockout Indicator (LO)

Soft Alarm (SO)

Remote On / Off (Enable) (RO)

Boiler Outlet

Temperature

(BO, BC)

Boiler Inlet

Temperature

(BI, BC)

Return

Water

Boiler

Circulator

System

Circulator

System

Supply Water

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

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”.

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.

Sage Boiler Control Instruction Manual Page 15 of 56

Product Features

Auxiliary Device Control

Standby System Pump

Start/Stop (SO)

Fresh Air

Supply

Modbus RS-485, RJ-11

Connection

M

M

System Pump

Feedback (SI)

Spare Output (VI)

System Pump

Start/Stop (SP)

Boiler Pump

Start/Stop (BP)

Mixing Valve

Control (MR, MS)

System

Supply Water

Return

Water

Combustion Air

Damper

Open/Close (SO) Boiler Outlet

Temperature

(BO, BC)

Boiler Inlet

Temperature

(BI, BC)

Energy Management

System (EMS)

Interface

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 pre-

purge, 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 16 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 active

and a manual reset may be required

SCREEN 2 line by 16 character display provides operational, alarm,

sequence status, configuration and diagnostic user interface

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): Press ENTER to change into Edit

Mode or select a menu or menu item

Edit Mode (blinking text): Press ENTER to save the current

value. Press MENU to cancel the current editing operation

UP, DOWN Select Mode (steady text): Press UP, DOWN to change the

selected display and move up and down menu items.

Edit Mode (blinking text): Press UP, DOWN to increases or

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

Sage Boiler Control Instruction Manual Page 17 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:

Boiler State

Standby boiler state shown, refer to the top of page 6 &

7 for explanation of each boiler state

Alarm Message

Low Inlet Temp alarm shown, refer to page 41 for

explanation of all possible alarm messages, the

alarm line is left blank when no alarm is active

OUT Boiler Outlet Temperature

IN Boiler Inlet Temperature

RST Remote System Temperature

(visible when ‘Remote Sensor’ = Display Only or

Control)

OA Outside Air Temperature

(visible when ‘Outdoor Sensor’ = Display Only or

Outdoor Reset)

OUT or RST Boiler Outlet or Remote System Temperature

(Remote System when ‘Remote Sensor’ = Control)

SP Active Setpoint

MOD RATE Modulation Rate

SH Space Heating (active when DH is not)

DH Domestic Hot Water Priority

(visible when ‘DHWP’ = Yes and DP input is true)

In Boiler Inlet Temperature

SP Min In H2O Temp

MIX VALVE Modulation Rate

Control Mode Outlet Sensor & Local SP Mode message shown, refer

to page 2 for an overview of each control mode

LEAD BOILER (0 – 8) Lead Boiler, when zero is displayed modulating

lead-lag functions are not available

CYCLES Number of boiler cycles

HOURS Number of boilers operating hours

Standby

Low Inlet Temp

In 180F SP 130F

MIX VALVE 100%

OUT 189F SP 180F

MOD RATE SH 100%

Outlet Sensor &

Local SP Mode

OUT 189F IN 180F

RST 189F OA 180F

Cycles #,###,###

Hours #,###,###

LEAD BOILER 8

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.

Sage Boiler Control Instruction Manual Page 18 of 56

Front Panel

Display Navigation

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

DISPLAY MODE

BOILER CONFIG

SYSTEM CONFIG

SETUP

SETPOINTS

COMMUNICATION

DIAGNOSTICS

SECURITY

MANUAL MODE

Arrow Keys:

Up / Down

through Lists

BOILER CONFIG

SYSTEM CONFIG

SYSTEM

SETPOINTS

DIAGNOSTICS

DISPLAY MODE

SETUP

SECURITY

ENTER

Main Menu

Sub Menus

COMMUNICATION

MANUAL MODE

MENU

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)

MENU

Sage Boiler Control Instruction Manual Page 19 of 56

Front Panel

Setpoints Menu

Time

Deg F

175

185

180

Water

Temperature

On Point

Operational SP

Off Point

Call For Heat

Relay (CH)

Call For Heat Settings

No. Factory

Setting Range / Choices Parameter and Description

70 180 60 F to 230 F Operational Setpoint

Setpoint used in Local Setpoint Mode when not servicing a Domestic Hot Water

Priority (DHWP) request

71 -5 0 F to –99 F On Point

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

setpoint.

72 15 0 F to 99 F Off Point

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

setpoint.

73 210 60 F to 230 F

High Temp Stop

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

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.

74 180 140 F to 230 F

*DHWP Setpoint

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

(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.

75 60 40 to 90 F

*WWSD Setpoint

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

77 140 60 F to 230 F Min SP

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.

79 130 110 F to 180 F *Min In H2O Temp.

Minimum Inlet Water Temperature setpoint used as the Mixing Valve inlet

temperature setpoint.

80 50 20 F to 50 F *Max H2O Delta T

Maximum Water Differential (Boiler Outlet minus Boiler Inlet) Temperature

setpoint used as the Mixing Valve differential temperature setpoint.

81 40 20 F to 50 F Max Delta T Hold

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

Sage Boiler Control Instruction Manual Page 20 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 facing 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 Carton and apply thread

sealant to the threads between the probe and hex shoulder.

d. Install the sensor in the ½” supply manifold 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 sensor 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 wiring 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 21 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 near 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 near the SBC.

c. 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.)

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

Sage Boiler Control Instruction Manual Page 22 of 56

Installation

Mounting & Wiring Sensors (Cont.)

Figure 1: Installation of SBC Components (Part 1)

Sage Boiler Control Instruction Manual Page 23 of 56

Installation

Mounting & Wiring Sensors (Cont.)

Figure 2: Installation of SBC Components (Part 2)

Sage Boiler Control Instruction Manual Page 24 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 Carton 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”.

V9

V11

Figure 3

Sage Boiler Control Instruction Manual Page 25 of 56

Installation

Terminal Layout

Remote System Temperature

(10k ohm Thermister, 5Vdc)

Outside Air Temperature

(10k ohm Thermister, 5Vdc)

Domestic Hot Water Priority

Local / Remote

Remote On / Off (Enable)

Spare Input (Programmable)

12 Vdc Common

Remote Firing Rate or

Setpoint Input (0-10 Vdc)

Mixing Valve Output

(4-20 mAdc)

Alarm Indicator

Vent Inducer Start/Stop

Boiler Pump Start/Stop

System Pump Start/Stop

Spare Output (Programmable)

12Vdc Common

CA

OO

Alternate Connection For

Outside Air Temperature and

Remote System Temperature

(10k ohm Thermister, 5Vdc)

Call For Heat Output

Low Water Cutoff Switch Input Boiler Outlet Temperature

(10k ohm Thermister, 5Vdc) Common

Boiler Inlet Temperature

Boiler Peer-To-Peer

Communication

Network

V- V+ P- P+

GP WFHL

Power Common (-24 Vac)

Power Supply (+24 Vac)

Flame Safeguard Alarm

(24 Vac)

Fuel Valve Energized

(24 Vac)

P-, P+ - Firing Rate Demand (0-10 Vdc, PWM)

V-, V+ - Firing Rate Demand (0-10Vdc)

OO - Burner On/Off Switch

WF - Low Water Flow Switch

GP - Gas Pressure Switch

HL - Operating or High Limit

CA - Low Combustion Air Flow

RJ-45

(8 pin)

O+

O-

O-

R+

R+

R-

R-

DP

O+

LR

RO

SI

C

C

C

SP

BP

VI

LO

C-

C+

MR

MS

SO

C

C

BC

BO

BI

CH

LC

CPRALCS

RJ-11

(6 pin)

12 Vdc,

0.5 A max total

for LO, VI, BP,

SP and SO

!

24

Vac

12

Vdc

Label 901 a

24

Vac

Sage Boiler Control Terminal Arrangement (rear view)

Sage Boiler Control Instruction Manual Page 26 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 27 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.

Two Boiler

RJ45 Connection Diagram

(Refer to Note 2)

Boiler 1

Boiler 2

Multiple Boiler Connection Diagram

(Using the extra O+, O-, R+ & R- terminals to daisy chain

the boilers together )

Outside Air

Temperature

Remote

System

Temperature

O+

O-

O-

R+

R+

R-

R-

O+

Alarm

BOILER RUNNING

Power

O+

O-

O-

R+

R+

R-

R-

O+

Alarm

BOILER RUNNING

Power

Connects to

Up to 8 Boilers

Boiler 1

Boiler 2

Outside Air

Temperature

Remote

System

Temperature

O+

O-

O-

R+

R+

R-

R-

O+

Alarm

BOILER RUNNING

Power

RJ-45

O+

O-

O-

R+

R+

R-

R-

O+

Alarm

BOILER RUNNING

Power

RJ-45

RJ-45

RJ-45

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 28 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.

Sage Control

Sage Control

Two Boiler

RJ11 Connection Diagram

Boiler 1 Boiler 2

RJ11

RJ11

Sage ControlSage Control

Sage Control

Multiple Boiler

RJ11 Connection Diagram

RJ11

RJ11 Splitter

(Not Included)

Connects to

Up to 8 Boilers

Boiler 1 Boiler 2 Boiler 3

RJ11

RJ11

RJ11 Splitter

(Not Included)

Or Building

Automation System

(BAS) Modbus

Connection

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-peer 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 state). 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 Slot

Number Connection

Black 1 A

Red 2 B

Green 3 B

Yellow 4 A

Notes

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

connect each boiler.

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

between boilers must be kept under 25 feet (average distance between all boilers).

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

(motors, fluorescent lights, contactors, spark generators, etc.). Use a separate conduit and junction box from

the power wiring.

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

Sage Boiler Control Instruction Manual Page 29 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. Factory

Setting Range / Choices Parameter and Description

90 Peer to

Peer Peer to Peer

Modbus

Protocol

Selects between Peer-To-Peer (multiple boiler Lead/Lag control network) and

a Modbus slave communication.

91 1 1-247 Modbus Address

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

equals Modbus.

92 19.2 9.6

19.2

38.4

Baud Rate

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

Modbus.

93 None Odd

Even

None

Parity

Only visible when Protocol equals Modbus.

94 30 1-120

Seconds Timeout

Only visible when Protocol equals Modbus.

95 Messages Rcvd

Diagnostic tool used to confirm wiring and Modbus master configuration.

Only visible when Protocol equals Modbus.

96 Messages Sent

Diagnostic tool used to confirm wiring and Modbus master configuration.

Only visible when Protocol equals Modbus.

97 1 1 to 8

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.

98 - - 6 - - - 321

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

MENU

ENTER

Sage Boiler Control Instruction Manual Page 30 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 successful 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 identical

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 31 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 Outdoor Air Reset Enable/Disable Disable Enable

00002 Domestic Hot Water Priority (DHWP) Disable Enable

00003 Local / Remote Local Remote

00004 Remote On / Off Modbus Command Y Off On 1

00005 Spare Input (Programmable) Off On

00006 Low Water Cutoff Switch Off On 2

00007 Burner On / Off Switch Off On 2

00008 Low Water Flow Off On 2

00009 High and Low Gas Pressure Switches Off On 2

00010 Operating or High Limit Off On 2

00011 Low Combustion Air Flow Off On 2

00012 Fuel Valve Energized Off On

00013 Flame Safeguard Alarm Off On

00014 Call For Heat (CFH) Off On

00015 General Alarm Off On 4

00016 Vent Inducer Off On

00017 Boiler Pump Off On

00018 System Pump Off On

00019 Spare Output (Programmable) Off On

00020 State Boiler Disabled Off On 3

00021 State Weather Shutdown Off On 3

00022 State Lockout Off On 3

00023 State Pump Purge Off On 3

00024 State Limit Hold Off On 3

00025 State Purge/Pilot Ign Off On 3

00026 State Low Fire/Ignition Off On 3

00027 State Main Ignition Off On 3

00028 State Low Fire Hold Off On 3

00029 State Boiler Running Off On 3

00030 State Fan Post Purge Off On 3

00031 State Pump Cool Down Off On 3

00032 State Standby Off On 3

00033 Annunciator Low Water Level Off On 4

00034 Annunciator Off Switch Off On 4

00035 Annunciator Low Water Flow Off On 4

00036 Annunciator Fuel Limit Off On 4

00037 Annunciator High Temp Limit Off On 4

00038 Annunciator Low Air Flow Off On 4

00039 Annunciator FSG Lockout Off On 4

00040 Annunciator Outlet Temp Fail Off On 4

00041 Annunciator Inlet Temp Fail Off On 4

00042 Annunciator OA Temp Fail Off On 4

Sage Boiler Control Instruction Manual Page 32 of 56

Installation

RS485 Modbus Network

Modbus Addresses (continued)

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

00043 Annunciator Remote Temp Fail Off On 4

00044 Annunciator Remote In Fail Off On 4

00045 Annunciator Comm Fail Off On 4

00046 Annunciator Low Inlet Temp Off On 4

00047 Annunciator Memory Failure Off On 4

Modbus

Register

Address

Description Read/

Write

Engineering

Units for

Register

= 0

Engineering

Units for

Register

= 100

Units Not

es

40001 Boiler Outlet Water Temperature -50 300 F

40002 Boiler Inlet Water Temperature -50 300 F

40003 Outside Air Temperature -50 300 F

40004 Boiler Actual Setpoint 60 230 F

40005 Remote System Temperature -50 300 F

40006 Remote Firing Rate or Remote Setpoint Y 0 100 or 300 % or F 1

40007 PCB Temperature Sensor -50 300 F

40008 Firing Rate Output to Mod Motor 0 100 %

40009 Minimum Return Temperature Setpoint 110 180 F

40010 Mixing Valve Output 0 100 %

40011 Control Mode 1 7

Notes

1. After a Modus communication failure, while using the Modbus connection to monitor or control the boilers, the

‘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

Sage Boiler Control Instruction Manual Page 33 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. Factory

Setting Range / Choices Parameter and Description

1 Deg F Deg F

Deg C Display Units

Selects how temperature parameter values are displayed.

2 None

None

On Always

Purge

Lead On

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

during the fan pre-purge, while the boiler is running and during

fan post purge when a lag boiler.

3 15 0 to 600

Seconds

Pump Prepurge

Sets length of time the boiler pump will be run prior to closing the “Call for

Heat” relay (CH).

4 5 0 to 20

C or F

Postpurge Delta

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 No

Yes Mixing Valve

Enables the mixing valve control output and user display.

6 Yes No

Yes Inlet Sensor (Return Sensor)

Enables the return temperature display and control logic.

7 -

hour : minute

month / day / year Set Time/Date

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

8 No No

Yes

Fuel Limit

Specifies a Fuel Limit such as high and low fuel gas pressure switches are

connected to input (GP). Enables Fuel Limit Hold and alarm messages.

9 Off

Off

Sys Pump

Feedback

Low Fire

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.

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.

10 Off

Off

CAD

System Pump BU

Soft Alarm

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 BU: Closes when System Pump output is activated but the

System Pump Feedback indicates the Primary System

Pump is not operating.

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

active, or a condition is preventing a boiler start,

including Off Switch.

MENU

ENTER

Sage Boiler Control Instruction Manual Page 34 of 56

Configuration & Tuning

System Configuration Menu

No. Factory

Setting Range / Choices Parameter and Description

20 Off Off

Isolated Demand

Shared Demand

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-To-

Peer network is adjusted above the DHWP Setpoint

21 No

No

Remote SP

Modbus SP

Remote Mod

Modbus Mod

Remote Control

Sets the remote (Energy Management System) control mode as follows:

No: Local setpoint and modulation rate is used.

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.

22 140 60 F to 140 F Remote 1.0 Volt=

Sets the temperature corresponding to input (C+,C-) 1Volts. Voltage below

1V is considered invalid, (failed or incorrect wired sensor).

23 220 150 F to 220 F 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).

24 No No

Display Only

Control

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

25 No No

Yes System Pump

Enables the System Pump output (SO)

27 No No

Yes

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

28 “Low

Water

Level”

16 Text

Characters

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 35 of 56

Configuration & Tuning

Setup Menu

No. Factory

Setting Range / Choices Parameter and Description

30 Off

Off

WWSD of Boiler

WWSD of Sys Pump

Both

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)

31 90 50 to 100

% Maximum

Modulation Rate

LL Start Trigger

Specifies the percent of maximum modulation rate the running boiler(s)

must reach before calling upon additional boilers for help.

32 10 0 to 50

% Modulation Rate

LL Stop Trigger

Specifies the modulation rate that the running boiler(s) must be below

before shutting down a lag boiler

33 5 60 to 900

Seconds

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

34 5 0 to 900

Seconds

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.

35 20 1 to 30

Minutes

%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

36 20 1 to 30

Minutes

%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

37 100 40 - 100

% Modulation Rate

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%.

38 1 1 - 10

Degrees/Minute

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.

39 220 100 - 240

C or F

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 36 of 56

Configuration & Tuning

Setup Menu (Continued)

No. Factory

Setting Range / Choices Parameter and Description

40 150 16 to 420

Seconds

Net Start Dwell

The Net Start Dwell Time Delay specifies the length of time the peer-to-

peer 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.

41 5 3 to 120

Seconds

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.

42 Disable Disable

Enable

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.

43 168 8-720

Hours

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.

Parameters 44 through 48 are found on the following page

49 100 0 to 100

% Full Scale

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 this parameter

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.

50 0 0 to 100

% Full Scale

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.

51 0 0-100

% Modulation Rate

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%.

52 0 0 to 100

% Modulation Rate

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.

53 600 10 to 1200

Seconds

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.

54 0 0 to 600

Seconds

Post Purge Time

Time modulation rate is held at Purge % setpoint after the Fuel Valve

Energized Input (CS) is de-energized.

Sage Boiler Control Instruction Manual Page 37 of 56

Configuration & Tuning

Setup Menu (Continued)

Outdoor Air Temperature

Hot Water Setpoint

190

70

210

90

170

150

130

110

-20 100800 204060

230

Min Setpoint

Max Setpoint

Boiler

Setpoint

Outdoor Air Temperature

Hot Water Setpoint

190

70

210

90

170

150

130

110

-20 100800 204060

Outdoor Design

Outdoor Set Up

Set Up

Temperature

Design

Temperature

Boiler Set Up

Boiler Design

230

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

44 No No

Display Only

Outdoor Reset

Outdoor Sensor

Enables the Outside Air Temperature display and control logic:

No Outside Air Input (O+O-) is ignored.

Display Only Do Not Calculate setpoint based on outdoor

temperature, Display Outside Air Temperature

Outdoor Reset Calculate the temperature setpoint based on outdoor

temperature using a reset curve defined by Outdoor

Set Up, Boiler Set Up, Outdoor Design and boiler

Design parameters

45 55 F 40 F to 100 F Outdoor Set Up

The Outdoor Set Up temperature is the outdoor temperature at which the

Boiler Set Up temperature is supplied.

46 140 F 140 F to 180 F

Boiler Set Up

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.

47 30 F -20 F to 50 F Outdoor Design

The Outdoor Design Temperature is the outdoor temperature at which the

Boiler Design temperature is supplied.

48 180 F 150 F to 220 F

Boiler Design

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

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 38 of 56

Configuration & Tuning

Setup Menu (Continued)

Slower Response Factory Setting Faster Response

PID (I)

PID (P) ½

Repeats/Minute 1

Repeats/Minute 2

Repeats/Minute

Faster Response 61 20 10 5

41 30 15 8

36 34 17 9

30 40 20 10

25 48 24 12

Local PID Factory Setting 20 60 30 15

15 80 40 20

12 100 50 25

10 120 60 30

9 140 70 35

Slower Response 8 160 80 40

Typical Sage Boiler Control PID Gain and Integral Settings

No. Factory

Setting Range / Choices Parameter and Description

55 41 0 to 10000

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.

56 15 0 to 10000

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.

57 0 0 to 10000

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.

58 20 0 to 10000 Remote PID P

Proportional Gain value for Remote System Temperature sensor control

Modes. Refer to Local PID P for explanation.

59 30 0 to 10000 Remote PID I

Integral Gain value for Remote System Temperature sensor control Modes.

Refer to Local PID I for explanation.

60 0 0 to 10000 Remote PID D

Derivative Gain value for Remote System Temperature sensor control

Modes. Refer to Local PID D for explanation.

Sage Boiler Control Instruction Manual Page 39 of 56

Configuration & Tuning

Setup Menu (Continued)

No. Factory

Setting Range / Choices Parameter and Description

61 15 0 to 10000

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.

62 40 0 to 10000

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.

63 0 0 to 10000

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.

64 15 0 to 10000

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.

65 40 0 to 10000

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.

66 0 0 to 10000

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 40 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. Factory

Setting Range / Choices Parameter and Description

101 Auto Man

Auto

Boiler Man/Auto

Man: Remain in Manual Mode

Auto: Return to Boiler Mode specified by parameter/boiler conditions

Activated only when in Supervisor Mode.

102 Varies 0 to 100

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.

103 Varies On,

Off

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.

104 Man Man

Auto

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.

105 Varies 0 to 100

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 41 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 messages are also stored in

the Fault History.

LCD Display

Alarm Message Recommended

Action Explanation

Low Water Level

O Flashing Red

Alarm Light

Manually Reset the

Low Water Cutoff 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.

Off Switch Turn Burner Switch

On 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

O Red Alarm

Light

Ensure boiler pump is

running and boiler

water flow is

unobstructed

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.

Fuel Limit

O Flashing Red

Alarm Light

Manually Reset the

Fuel pressure switch 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 Temp Limit

O Flashing Red

Alarm Light

Manually Reset the

High Temperature

Aquastat

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

O Flashing Red

Alarm Light

Check combustion air

blower and air

pressure switch

settings and wiring

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.

FSG Fault

O Flashing Red

Alarm Light

Manually Reset

Required, Refer to

Flame Safeguard

Manual corrective

actions

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.

Outlet Temp Fail

O Red Alarm

Light

Check wiring and

sensor 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

Inlet Temp Fail

O Red Alarm

Light

Check wiring and

sensor 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.

OA Temp Fail

O Red Alarm

Light

Check wiring and

sensor 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 Temp

Fail

O Red Alarm

Light

Check wiring and

sensor 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 42 of 56

Trouble Shooting

Alarm Messages (continued)

LCD Display

Alarm Message Recommended Action Explanation

Remote Input

Fail

O Red Alarm

Light

Check wiring and

Remote System 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

Comm Failure

O Red Alarm

Light

Check wiring and

Remote System

Confirm each boiler has

a unique address

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 Inlet Temp

O Red Alarm

Light

Check wiring and

sensor

Check return water

temperature. Consider

system or operational

changes to avoid low

temperature events

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

O Red Alarm

Light

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)

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 43 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:

Boiler Inlet Temperature History

Display Description

13:31 09/10/06

BOT Sensor Fail

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.

8:45 09/10/06

Low Temp: 130F

8:45 09/10/06

Low for 1:00:02

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

Spare Input

Off

Low Water Cutoff

Off

Burner On / Off

Off

Low Water Flow

Off

Fuel Limit

Off

Oper./High Limit

Off

Low Air Flow

Off

Fuel Energized

Off

FSG Alarm

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

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.

These displays show the status of the corresponding Discrete Input

MENU

ENTER

Sage Boiler Control Instruction Manual Page 44 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

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

Boiler Outlet

0%

Boiler Inlet

0%

Outside Air

0%

Remote System

0%

Remote Input

0%

PCB Temperature

0%

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

Boiler Demand

0%

Mix Valve Demand

0%

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 45 of 56

Trouble Shooting

Diagnostic Menu (Continued)

System Menu Display Description

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.

Param Code

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

.

Software Rev.

S 3.24

PCB Temperature

70 F

Actual RST

32 F

Actual OAT

-40 F

Actual BOT

32 F

Actual BIT

32 F

Clr BIT Hist

No Action

Clr Cycle Cnt

No Action

Factory Defaults

No Action

Clr Alarm Hist

No Action

Clr Run Time Cnt

No Action

Sage Boiler Control Instruction Manual Page 46 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 47 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. The display will jump to the Access

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. Factory

Setting Range / Choices Parameter and Description

Basic

Supervisor

Access Level

Basic: Select Basic Level Access to parameters/variables

Supervisor: Select Password Level Access to parameters/variables

0 to 9999

Enter Password

Allows user to enter password to gain access to both Supervisor Access

and Factory Access Levels.

Factory

Password

is 86 0 to 9999

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.

Sage Boiler Control Instruction Manual Page 48 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 Rating

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 Rating

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

R+

R - Remote System Temperature 10k Thermister, 5Vdc, 5 mA max load

C+

C - Remote Modulation Rate or Remote Setpoint 0-10 Vdc (~100K ohm impedance)

1Vdc = 0%, 9Vdc = 100%

Analog Outputs:

Terminal Description Rating

P+

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

V+

V-

Modulation Rate Output to Mod Motor 0 – 10 V, 5 mA max

MS

MR Mixing Valve Output 4-20mA

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

Sage Boiler Control Instruction Manual Page 49 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 used to power the time of day and date clock chip when the 24 Vac power

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 Repair Part Number

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

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 air 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 50 of 56

Appendix A

Parameter Summary

Network

Relevant* Parameter Range / Choices Factory

Setting Security

Level** Page

Boiler Configuration Menu

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

Yes Boiler Pump None / On Always / Purge / On Lead None Supervisor 31

Update If Purge, set Pump Prepurge 0 to 600 seconds 15 Supervisor 31

Update Postpurge Delta 0 to 20 F 5 Supervisor 31

- Inlet Sensor Yes / No Yes Supervisor 31

- Mixing Valve Yes / No No Supervisor 31

Update Set Time/Date hour : minute month / day / year Basic 31

Update Fuel Limit Yes / No No Factory 31

Update Spare Input Off / Sys Pump Feedback / Low Fire Off Supervisor 31

Update Spare Output Off / CAD / Sys Pump BU / Soft Alarm Off Supervisor 31

System Configuration Menu

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

Yes Remote control No / Remote SP / Modbus SP /

Remote Mod / Modbus Mod No Supervisor 32

- Remote 1 volts = 60 F to150 F 140 Supervisor 32

- Remote 9 volts = 150 F to 230 F 220 Supervisor 32

Yes Remote Sensor No / Display Only / Control No Supervisor 32

Yes System Pump Yes / No No Supervisor 32

Update LWC or CAD Yes / No No Supervisor 32

Update Alarm Message Low Water level Supervisor 32

Setup Menu

Yes WWSD Off / WWSD of Boiler / WWSD of Sys

Pump / Both Off Basic 33

Yes LL Start Trigger 50 to100% of Modulation Rate 90 Supervisor 33

Yes LL Stop Trigger 0 to 50% of Modulation Rate 25 Supervisor 33

Yes Boiler On Delay 0 to 900 seconds 5 Supervisor 33

Yes Boiler Off Delay 0 to 900 seconds 5 Supervisor 33

Yes %FR On Delay 1 to 30 minutes 20 Factory 33

Yes %FR Off Delay 1 to 30 minutes 20 Factory 33

Yes High Fire Limit 40 - 100 % Modulation Rate 100 Supervisor 33

Yes Deg/Min Hold Off 1 - 10 Degrees / Minute 1 Factory 33

Yes Cutback Setpoint 100 F - 240 F 220 Factory 33

Yes Net Start Dwell 16 to 420 Seconds 120 Factory 34

Yes Limit Fault Time 3 to 120 Seconds 5 Factory 34

Yes Rotation Enable / Disable Disable Basic 34

Yes Rotation After 8 to720 hours 48 Basic 34

Yes Outdoor Sensor No / Display Only / Outdoor Reset No Basic 35

Yes Outdoor Set Up 40 F to 100 F 55 Basic 35

Yes Boiler Set Up 80 F to 180 F 140 Basic 35

Yes Outdoor Design - 20 F to 50F 30 Basic 35

Yes Boiler Design 80 F to 220 F 180 Basic 35

∗ 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.

Sage Boiler Control Instruction Manual Page 51 of 56

Appendix A

Parameter Summary (continued)

Network

Relevant* Parameter Range / Choices Factory

Setting Security

Level** Page

Setup Menu (continued)

- Blower Spd High 0 to100 % of full scale 100 Factory 34

- Blower Spd Low 0 to100 % of full scale 0 Factory 34

- Low Fire Spd 0 to100 % Modulation Rate 0 Factory 34

- Fan Purge Spd 0 to100 % Modulation Rate 100 Factory 34

Yes Low Fire Hold 0 to 1200 sec 0 Factory 34

Yes Post Purge Time 0 to 600 sec 0 Factory 34

Yes Local PID P 0-10000 20 Supervisor 36

Yes Local PID I 0-10000 30 Supervisor 36

Yes Local PID D 0-10000 0 Supervisor 36

Yes Remote PID P 0-10000 20 Supervisor 36

Yes Remote PID I 0-10000 30

Supervisor 36

Yes Remote PID D 0-10000 0

Supervisor 36

Yes Mixing Valve P 0-10000 15 Supervisor 37

Yes Mixing Valve I 0-10000 40 Supervisor 37

Yes Mixing Valve D 0-10000 0 Supervisor 37

Yes Mixing Delta T P 0-10000 15 Supervisor 37

Yes Mixing Delta T I 0-10000 40 Supervisor 37

Yes Mixing Delta T D 0-10000 0 Supervisor 37

Setpoint Menu

Yes Operational Setpoint 60 F to 230 F 180 Basic 19

Yes On point 0 F to – 99 F -5 Basic 19

Yes Off Point 0 F to 99 F 5 Basic 19

Yes High Temp Stop 60 F to 230 F 200 Basic 19

Yes DHWP setpoint 140 F to 230 F 180 Basic 19

Yes WWSD setpoint 40 F 90 F 70 Basic 19

Yes Max SP 140 F to 230 F 230 Supervisor 19

Yes Min SP 60 F to 230 F 140 Supervisor 19

Yes Min BIT 110 F to 235 F 120 Factory 19

Update Min Inlet H2O Temp 110 F to 180 F 130 Supervisor 19

Update Max H2O Delta T 20F to 50 F 50 Supervisor 19

Update Max Delta T Hold 20F to 50 F 40 Supervisor 19

Communication Menu

- Protocol Peer to Peer / Modbus Peer to Peer Supervisor 27

- Modbus Address 1-247 1

Supervisor 27

- Baud Rate 9.6 / 19.2 / 38.4 19.2 Supervisor 27

- Parity Odd / Even / None None Supervisor 27

- Timeout 1 Second to 120 Seconds 30 Supervisor 27

- Boiler Address 1 to 8 1 Supervisor 27

∗ 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.

Sage Boiler Control Instruction Manual Page 52 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 Circle one: No Remote SP Modbus SP

Remote Mod Modbus Mod

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

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

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Appendix B

Customer Parameter Worksheet (continued)

Parameter Range / Choices Units

Setpoint Menu

Operational Setpoint F

On point F

Off Point F

High Temp Stop F

DHWP setpoint F

WWSD setpoint F

Max SP F

Min SP F

Min Inlet H2O Temp F

Max H2O Delta T F

Max Delta T Hold F

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 Seconds

Boiler Address

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SERVICE RECORD

DATE SERVICE PERFORMED

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