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Burnham Sage Boiler Control Instruction Manual

1. DOMESTIC HC THERMOSTAT INPUT INP IPU r Q SG M CO lava ye S So lt AUN f Nee LN AM MJ E O S ER Y D N pe PA CoO JE TK UN N 1 R p V rad v MES PE Sy y JC UNE fe NY LI ae P aS NON DP NM JEN i A LR NE PEN OA MA ix RO DA KC ON SI N m AN ine st j STA X p P A VEA N Y F MI E L Y N VIX P fk N imd FF ENABLE e a LOCAL REMOTE O SPARE INPUT MUL TIPE il LERS UTSI AIR AND REMO Te SEAS EMPERA TURE R SHARING ee PE L System Water Temperature Sensor Y X CUMMUNICA TIL BUS NETWORK SELAYS eae qae OCKOI OCKOU INDICATO 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 n
2. 40009 Minimum Return Temperature Setpoint 110 1800 JE 40010 Mixing Valve Output 0 10 j 40031 jCotniMoe J 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
3. Remove control power from the boiler Connect the boiler to the network using a RJ11 ended telephone cable Apply control power to the boiler The network will auto detect the new boiler and assign it a position in the sequence based on the boiler address co N A OL es When a boiler is operated as a stand alone boiler away from the network it establishes itself as a lead boiler If this stand alone boiler is simply re connecting to a network of operating boilers there is a potential that boiler operation will be disrupted as the new boiler becomes lead This potential is avoided by following the above Re Establishing procedure Sage Boiler Control Instruction Manual Page 30 of 56 Installation RS485 Modbus Network The Sage Boiler Control includes a dependable Modbus communication network This network allows boilers to be controlled and or monitored by a remote system via a RS485 Modbus communication network Each Sage Boiler Control is a Modbus slave with the following available boiler information Modbus Addresses Coil Address Read Write 00001 OutdoorAirResetEnable Disable___ Disable Enable 00002 DomesticHotWaterPriorty DHWP Disable Enable 000083 Local Remoe Local Remote 00004 Remote On Off Modbus Command Y Of On i 00005 Spare Input Programmable Of On 00006 Low Water Cutoff Switch Of On 2 00007 Burner On O
4. On f4 00086 AnnunciatorFuelLimit off On f4 00037 Annunciator High Temp Limit o On f4 00088 Annunciator Low Air low Ot On f4 00089 Annunciator FSG Lockout of On f4 00040 Annunciator Outlet Temp Fail o On f4 00041 Annunciator Inlet Temp Fal Oft On f4 00042 Annunciator OA Temp Fail Ot On j4 Sage Boiler Control Instruction Manual Page 31 of 56 Installation RS485 Modbus Network Modbus Addresses continued 00043 Amnunciator Remote Temp Fail o On f4 00044 Annunciator Remote In Fail off On f4 00045 Annunciator Comm Fail otf On f4 00046 AnnunciatorLowInletTemp Ot On f4 00047 AnnunciatorMemory Failure On ja Engineering Engineering Senan Read Units for Units for Not egister escription Write Register Register nits D Address 0 100 40001 Boiler Outlet Water Temperature 50 30 F 40002 Boiler Inlet Water Temperature so 30 F 40003 Outside Air Temperature 5o 30 JE 40004 Boiler Actual Setpoint 6 amp 0 230 JE 40005 Remote System Temperature 5o 830 E 40006 Remote Firing Rate or Remote Setpoint v o 1000r300 orF 1 40007 PCBTempertueSensr 50 30 JE 40008 Firing Rate Output to ModMotr 0 10
5. Remote Input LR is open Remote Input C C is ignored and Remote Sensor amp 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 Page 12 of 56 Product Features Energy Management System EMS Boiler Control continued Display Shows Remote Control Mode Return Water Boiler Circulator Boiler Outlet gt Temperature BO BC System Boiler Inlet Temperature EMS System Hardwired Connections BI BC Lockout Indicator LO Soft Alarm SO Remote On Off Enable RO Remote Setpoint C C RJ11 RS 485 Communication Circulator System Supply Water Modbus Network EMS Monitoring and Control Remote Firing Rate via Modbus Remote on off via Modbus 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
6. k Any damage caused by water side clogging due to dirty systems or corrosion products from the system Il Any damage resulting from natural disaster m Damage or malfunction due to the lack of required maintenance outlined in the Installation and Operating Manuals furnished with the unit 6 Exclusive Remedy Burnham Commercial obligation for any breach of these warranties is limited to the repair or replacement of its parts not including labor in accordance with the terms and conditions of these warranties 7 Limitation of Damages Under no circumstances shall Burnham Commercial be liable for incidental indirect special or consequential damages of any kind whatsoever under these warranties including but not limited to injury or damage to persons or property and damages for loss of use inconvenience or loss of time Burnham Commercial liability under these warranties shall under no circumstances exceed the purchase price paid by the owner for the commercial grade boiler involved Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you 8 Limitation of Warranties These warranties set forth the entire obligation of Burnham Commercial with respect to any defect in a commercial grade boiler parts or accessories and Burnham Commercial shall have no express obligations responsibilities or liabilities of any kind whatsoever other than those set f
7. A ANN A AAA OA A o A NM OOOO A pd pe TS MEN mE mE mE mE mE mE oo I Lj mE Sage Boiler Control Instruction Manual Page 52 of 56 Appendix B Customer Parameter Worksheet continued Range Choices Setpoint Menu Operational Setpoint A Onpoint 000000 o CA High Temp Stop fF DHWP setpoint WWSD setpoint IMaxXSP o 0 O OOOO O Communication Menu Circle one Peer to Peer Modbus NENNEN Modbus Address A Baud Rate Circle one 19 2 384 EEEN 9 6 Pate ide one Odd Even None Timeout Seconds Boiler Address o Sage Boiler Control Instruction Manual Page 53 of 56 SERVICE RECORD DATE SERVICE PERFORMED Sage Boiler Control Instruction Manual Page 54 of 56 THIS PAGE LEFT BLANK INTENTIONALLY Sage Boiler Control Instruction Manual Page 55 of 56 Sage Boiler Control Instruction Manual Limited Warranty For Commercial Grade Boilers Using Cast Iron Carbon Steel or Stainless Steel Heat Exchangers and Parts Accessories Subject to the terms and conditions set forth below Burnham Commercial Lancaster Pennsylvania hereby extends the following limited warranties to the original owner of a commercial grade water or steam boiler or Burnham Commercial supplied parts and or accessories manufactured and shipped on or after October 1 2008 ONE YEAR LIMITED WARRANTY ON COMMERCIAL GRADE BOILERS AND PARTS ACCESSORIES SUPPLIED BY BURNHAM COM
8. II fH Sgr su snqpolw UD3IMS 930Uueg 2207 9 Jgeu3 HO UO ajouuay JO3e2ipu 310520 UJ9ojs S uoneuuoiny 6uiping 043u02 19 l0g abes O QUOD UeuuLid OJJUO PERERA YMS J MOl ANY oJnjeJjoduuo 3enno 19 109 yw eun3eJeduuo u6iH UDIIAS JJOIND JEM MOT UD3IMS MO 4 1 7EM MOT uonsnquio JOJON JO ahpOlA eJnjeJeduue 39 u 19 10g dund Jeyiog EDU RN NY O 3u0D 3NEAN BUIXIN HE SSYIIMS onJ Ajddns any U23IMS X JJO UO J9 rog yee f J9 tog Jeduueq A ddns JV uonsnquuo JV USa13 Jy SPISMO JH Ajddnsg J938AA 10H UD3IMS id UJo1sS S oJnjeJjeduue L UJ9jS S 2 0U9y dund Wa SAS peqpoej dund uue1s S dund uue1s s qpuexs Jaye AA uunjieu Page 5 of 56 Sage Boiler Control Instruction Manual Product Features Boiler Sequence c BOILER STATE 2 le 2 v c S a c j TESEI El lo 2913 LCD Display 5 z Ss S o o 5 ole lsi s x 98 iSc o 9 9 z 2 c Q a 2 n8 z3 z 2igoe ei st ie g2g ml 8 c Q O zi a n E O O O O D o ns LL mE LL a o E 9 ES O c Kb o o S2 8 amp S 5 3 G O S 5 E a misso 1 0 6 3 46 1 S 3 M u a Parameter Notes a _b8c a a dd 53 54d Boiler Disable or Remote On Off Ro Boiler Enable Disable On Outdoor Air Temp gt o o 4430 Warm Weather Shutdown Setpoint 75 Domestic
9. R a c e Gannects io cocco ERES A Up to Eight Boilers System ES Circulator NY RJ11 RS 485 Peer to Peer System Network Supply Water Remote Sensor amp Remote SP Mode Application Diagram Showing relevant connections for 3 boilers typical for up to 8 Features Selecting This Control Mode Setpoints To select Remote Sensor amp Remote SP Mode set the 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 96 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 Sage Boiler Control Instruction Manual 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
10. 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 9096 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 Page 4 of 56 Introduction Overview Uuono euuo
11. Setup Menu Continued Factory m EU Setting Range Choices Parameter and Description 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 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 16 to 420 Io Seconds a os Seconds Call for Heat If the Limit Fault time is exceeded before the limits are energized the next boiler Call for Heat is immediately initiated Disable Rotation 42 Disable Enable Enables the lead boiler role to be rotated through the boilers on the network When disabled the boiler with the lowest network address is lead Rotate after opecifies number of hours cumulative a lead boiler runs before passing the lead to another boiler 43 168 Vio 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 Blower Spd High Linka
12. Wrench the sensor until watertight Remove the other 1 2 temperature sensor from the Sage Boiler Control Parts Carton and apply thread sealant to the threads between the probe and hex shoulder 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 2 or use a 3 x 3 x 12 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 DIOVOA 2 m FRONT VIEW HACK VIEW V9 40009800 L TS J G Tm N D D E 2 E f OO FRONT SECTION REAR SECTION V11 Figure 3 Sage Boiler Control Instruction Manual Page 24 of 56 Installation Terminal Layout Alternate Connection For RJ45 Outside Air Temperature and 8pin Remote System Temperature 10k ohm Thermister 5Vdc Low Water Cutoff Switch Input 24 Call For Heat Output Vac QO Outside Air Temperature 10k ohm Thermister 5Vdc CA Low Combustion Air Flow HL Operating or High Limit 24 GP Gas Pressure Switch Vac Remote System Temperature du a rod A Je uet 10k ohm Thermister 5Vdc OO Burner On Off Switch d oar a V V Firing Rate Demand 0 10Vdc O
13. Hot Water P riority DP 2074 Domestic Hot Water Demand Monitored Low Fire Hold EERE Fuel Valve Energized esf o A System Pump Feedback EBEN System Pump Feedback Monitored Call For Heat Call For Heat BOBC Recycling Limits c oo wr 8 27 ER Non Recyding Limits c Combustion Air Flow CA Input Call For HeatRelay Lockout Indicator LO Manual ResetRequired Spare Output vi Boiler Pump BP a Boiler Pump On SS SS a AA A AA O System Pump sp 2500 System Pump On System Pump Backup Pump so o Starts in response to System Pump Feedback Input SI System Alarm SO Alarm Status is Monitored Mixing Valve Output a Modulat V V Blower High Speed 0 V V mney mm bas V V 0 V V Blower 0 Volts P P Interlock Inputs Relay Outputs co eo o 99 OC O P LL a uN m 2 o O c 2 pw i 2 O O Notes 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 Boiler Pump is On when the Boiler Pump is set to On Always and WWSD is set to WWSD of System Pump or Off System Pump is On when the System Pump is set to
14. 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 Range Choices Parameter and Description Setting Access Level Basic Basic Select Basic Level Access to parameters variables Supervisor Supervisor Select Password Level Access to parameters variables Enter Password Allows user to enter password to gain access to both Supervisor Access O to 9999 and Factory Access Levels Set Password Factory Holds the user defined password for the boiler A password 0 means Password 0 to 9999 no password protection Access Level will default to Supervisor L
15. SP and SO P P Firing Rate Demand 0 10 Vdc PWM Domestic Hot Water Priority Local Remote 12 Power Common 24 Vac Remote On Off Enable Vdc Power Supply 424 Vac sl Spare Input Programmable Flame Safeguard Alarm c CA HL GP WF 24 Vac 12 Vde Common Fuel Valve Energized excu e Loses usse Hes 24 Vac Boiler Peer To Peer Communication Network 10k ohm Thermister 5Vdc Common Boiler Outlet Temperature Boiler Inlet Temperature 12Vdc Common Spare Output Programmable System Pump Start Stop Boiler Pump Start Stop Vent Inducer Start Stop Alarm Indicator Mixing Valve Output 4 20 mAdc Remote Firing Rate or Setpoint Input 0 10 Vdc Label 901a RJ 11 6 pin GOO GG G 9 9 0 9 9 9 9 Sage Boiler Control Terminal Arrangement rear view Sage Boiler Control Instruction Manual Page 25 of 56 Installation External Connections OTHE EN OIHERO s GND B Y UNIT ARTH AIX LAB CONNECI Qo CN gt Ut N MNADA JL BOARD WP MIXING VALVE us Ted UIT ADO REMOTE JOONTROL E Qd VDE Pan REMOTE SP OR y E MODULATION RATE
16. Time Cnt Clr Cycle Cnt Factory Defaults O Red Alarm Factory Level Light Password is required Sage Boiler Control Instruction Manual Page 42 of 56 Trouble Shooting Diagnostic Menu All values shown in Diagnostic Menu are for display only and cannot be adjusted by the operator Press and hold the key to leave the Display Mode and access the Main Menu Use the O O keys scroll down to the Diagnostic Menu and push the ares key Boiler Inlet Temperature History Display 13 31 09 10 06 BOT Sensor Fail 8 45 09 10 06 Low Temp ISDE 8 45 09 10 06 Low for 1 00 02 DEW Priority Off Local Remote Off Remote On Off Off Spare Input Off x 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 Y ON t Sage Boiler Control Instruction Manual Description FAULT HISTORY The last 10 alarms are stored in memory Use the arrow keys to scroll through the alarms Each alarm is displayed with the time and date it occurred BIT HISTORY The last 10 Low Inlet Temperature Events are stored in memory Each time the boiler inlet temperature is less than the Min In H2O Temp parameter a low temperature event is recorded The BIT History screen automatically toggles between the lowest temperature for the event and Duration Below Setpoint displays and provides time and date of each event
17. Typical Sage Boiler Control PID Gain and Integral Settings Factory mE EUM Setting Range Choices Parameter and Description 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 Ot primary PID modulation rate tuning adjustment and provides the immediate o 10000 modulation rate response Pick a gain based on the desired initial response The burner modulation rate can oscillate if the Proportional Gain is too large Local PID 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 56 O to 10000 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 59 Local PID D The Derivative gain value for boiler outlet temperature sensor control O to 10000 Modes A larger Derivative gain value produces a larger PID output contribution proportional to the rate of change of the error Setpoint Boiler Outlet Temperature When set equal to zero it has no effect on the output Remote PID P O to 10000 Proportional Gain value for Remote System Temperature sensor contr
18. 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 Ensure boiler pump is Low Water Flow Switch running and boiler Low water flow is preventing the boiler from starting If terminal WF does O Red Alarm water flow is not receive power and the Call For Heat output CH is powered the Low Light unobstructed Water Flow Message is displayed Fuel Limit Manually Reset the Low or High Gas Pressure Switch Fuel pressure switch The low or high gas pressure switch is preventing the boiler from starting O Flashing Red If terminal GP does not receive power and the Call For Heat output CH Alarm Light is powered the Fuel Limit Message is displayed High Temp Limit Manually Resetthe High Limit Temperature High Temperature The high temperature limit HL and operational temperature limit when Aquastat provided aquastat is preventing a boiler start If terminal HL does not O Flashing Red recelve power and the Call For Heat output CH is powered the High Alarm Light Temp Limit Message is displayed Low Air Flow Check combustion air Low Air Flow or Blocked Vent Switch Not Made blower and air The air flow and blocked vent switch when provided is preventing a boiler O Flashing Red pressure switch start If terminal CA does not receive power and the Call For Heat output Alarm Light settings and wiring CH is powered the Lo
19. 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 50 of 56 Appendix A Parameter Summary continued p Menu conti nue METE E A 0 to100 of full scale Factory BlowerSpdlow 0 t0100 96 of full scale 0 Factory 34 LowFireSpd 0 to100 Modulation Rate 0 Factory 34 FanPugeSpd O to100 Modulation Rate Factory Yes LowFieHod Oto1200sec 0 Factory 34 Yes Post Purge Time Oto600sec 0 Factory 34 Yes LoalPIDD A 201000 O Supervisor 36 Yes RemoePIDD 1 20 1000 O Superisor 36 Yes MiingVaveD 01000 S Supervisor 37 Yes MiingDela TD 01000 O Superisor 37 Setpoint Menu Communication Menu Protocol Z 2 Peer to Peer Modbus Le Modbus Address 1 247 Baud Rate 9 6 19 2 38 4 Pary Odd Eve Noe None Supervisor 27 jTimeu 1 Secondto 120 Seconds 30 Supemisor 27 BoilerAddress_________ ______ttos 1 Supervisor 27 Parameters ide
20. 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 Sage Boiler Control Instruction Manual 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
21. 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 Sage Boiler Control Instruction Manual following parameters System Configuration Menu Remote Control No Remote System Temperature Sensor Control Remote On Off Enable Inout 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 amp 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 Page 10 of 56 Product Features Energy Management System EMS Boiler Control Display Shows Outlet Sensor amp Remote SP Mode Return Water Boiler In
22. ignored Remote SP Remote Input C C is used as the temperature setpoint Parameter 22 amp 23 may be used to adjust the signal range Modbus SP RS485 Modbus 40006 is used as the temperature setpoint Remote Mod Remote Input C C is used as the modulation rate Modbus Mod RS485 Modbus 40006 is used as the modulation rate Remote 1 0 Volt Sets the temperature corresponding to input C C 1Volts Voltage below 1V is considered invalid failed or incorrect wired sensor Remote 9 0 Volt Sets the temperature corresponding to input C C 9 Volts Voltage above 9V is considered invalid failed or incorrect wired sensor Remote Sensor Enables the Remote System Temperature sensor display and control logic No Remote Sensor Input R R is ignored Display Only Remote Sensor Input R R is used for display only Control Remote Sensor Input R R is compared with the temperature setpoint to establish a modulation rate System Pump Enables the System Pump output SO LWC or CAD opecifies a Low Water Cut off Switch or Combustion Air Damper Fresh Air Damper Open switch is connected to input LC Enables Limit Hold and alarm messages Limit hold display message is described by parameter 28 Alarm Message Limit Hold and alarm message displayed corresponding to sensor connected to input LC The ENTER key and Up and Down arrow keys are used to change the text Message Page 34 of 56 C
23. rotating the lead boiler will move to the end of the lag order and the 1 lag boiler will become the lead The rest of the boilers will then move up in the lag order accordingly 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 Page 8 of 56 Product Features Single Boiler Control Display Shows Outlet Sensor amp Local SP Mode Return Water Outside Air Temperature O O Boiler Circulator Boiler Outlet ON Temperature PA eue ec eere pd System d Override Boiler Inlet Temperature EMS System Hardwired Connections Lockout Indicator LO Soft Alarm SO Remote On Off Enable RO RJ11 RS 485 Communication Peer To Peer Network Circulator Switch DP Domestic Hot Water DHW Supply System Supply Water for Modulating Lead Lag Or Modbus Network _ for Touch Screen or EMS Monitoring Outlet Sensor amp 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 th
24. 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 28 of 56 Installation Communication Continued The Sage Boiler Control communication selections are found on the Communication Menu Press and hold the wes key to leave the Display Mode and access the Main Menu Use the O O keys scroll down to the Communication Menu and push the ors key Communication Menu Factory m No Setting Range Choices Parameter and Description Protocol poda rd a Selects between Peer To Peer multiple boiler Lead Lag control network and a Modbus slave communication Modbus Address 91 1 1 247 Each boiler must be given a unique address Only visible when Protocol equals Modbus 9 6 l Baud Rate 19 2 Units are 1000 Bits Per Second KBPS Only visible when Protocol equals 38 4 Modbus Odd Pari N Only visible when Protocol equals Modbus one Messages Rcvd Diagnostic tool used to confirm wiring and Modbus master configuration Only visible when Protocol equals Modbus Messages Sent Diagnostic tool used to confirm wiring and Modbus master configuration Only visible when Protocol equals Modbus Boiler Address Each boiler must be given a unique addre
25. state and configuration of Spare Input after the Fuel Valve Energized Input CS is energized 0 to 600 Post Purge Time 54 Seconds Time modulation rate is held at Purge setpoint after the Fuel Valve Energized Input CS is de energized Sage Boiler Control Instruction Manual Page 36 of 56 Configuration amp Tuning Setup Menu Continued _ 230 Max Setpoint 230 em 7 Y 210 Boiler EE Design s Setpoint 190 E 190 Boiler Design 5 X Temperature z 170 2 170 3 8 150 2 Set Up 150 4 2 Boiler Set Up X Temperature Min Setpoint g 130 5 130 4 110 7 X 110 ale 90 X 90 70 20 O 20 40 60 c o YW D e o O O O O Jo O gt 5 O O 70 Outdoor Air Temperature Outdoor Air Temperature 20 0 20 40 60 80 100 80 100 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 Factory No Setting Range Choices 180 F 150 F to 220 F Sage Boiler Control Instruction M
26. the tapping in the manifold and that the sensor probe slides through this hole without interference Wrench the sensor until watertight Remove the other 1 2 temperature sensor from the Sage Boiler Control Parts Carton and apply thread sealant to the threads between the probe and hex shoulder Install the sensor in the 7 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 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 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 Hemove 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
27. 2 72 11307 78 172 1 350 66 424 23 74 10762 79 174 1 302 62 460 24 76 10247 80 176 1256 58 759 26 78 9760 81 178 1212 55 301 27 80 9298 82 180 14169 52 069 28 82 8862 83 182 1 29 49 047 29 84 8448 84 184 1 089 46 220 30 86 8 056 86 186 1 052 43 574 31 88 7 685 87 188 1016 41097 32 90 7333 88 190 9812 38 776 33 92 6999 89 192 9479 36 601 34 94 65682 90 194 9159 34 562 36 96 6382 9 196 8852 32650 37 98 6097 92 198 8557 30 856 38 100 5826 93 200 8273 29 171 27 590 40 104 5325 96 204 7738 26 104 24 707 42 108 4872 98 208 7243 23 394 43 110 4663 99 210 7009 22 159 20 997 46 114 4273 101 214 6568 19 903 18 873 17 902 49 120 3757 104 220 596 5 16988 50 122 360 o Sage Boiler Control Instruction Manual Page 46 of 56 Trouble Shooting Security Menu Passwords There are three Access Levels in the system Basic Supervisor and Factory e Atthe 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 e Atthe 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 e Atthe FACTORY Access Level all relevant internal parameters in the system will be visible and programmable The Basic Access
28. IG SYSTEM CONFIG SETUP SETPOINTS COMMUNICATION DIAGNOSTICS SECURITY MANUAL MODE Arrow Keys Up Down through Lists Sage Boiler Control Instruction Manual us Sub Menus DISPLAY MODE BOILER CONFIG SYSTEM CONFIG SETPOINTS COMMUNICATION DIAGNOSTICS SYSTEM SECURITY MANUAL MODE Display Mode Displays Boiler operating status Display Only Values Are Not Editable from this display Configuration and Setup Menus Sensor boiler and system options selections refer to page 31 Setpoints Menu Operational On Off Min amp 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 amp 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 Page 18 of 56 Front Panel Setpoints Menu Water Temperature Operational SP gt 180 lt OnPoint 175 Call For Heat Relay CH Call For Heat Settings S een Parameter and Parameter and Description Operational Setpoint JEJE Setpoint used in Local Setpoint Mode when not s
29. MERCIAL Burnham Commercial warrants to the original owner that its commercial grade water and steam boilers and parts accessories comply at the time of manufacture with recognized hydronic industry standards and requirements then in effect and will be free of defects in material and workmanship under normal usage for a period of one year from the date of original installation If any part of a commercial grade boiler or any part or accessory provided by Burnham Commercial is found to be defective in material or workmanship during this one year period Burnham Commercial will at its option repair or replace the defective part not including labor HEAT EXCHANGER WARRANTIES Burnham Commercial warrants to the original owner that the heat exchanger of its commercial grade boilers will remain free from defects in material and workmanship under normal usage for the time period specified in the chart below to the original owner at the original place of installation If a claim is made under this warranty during the No Charge period from the date of original installation Burnham Commercial will at its option repair or replace the heat exchanger not including labor If a claim is made under this warranty after the expiration of the No Charge period from the date of original installation Burnham Commercial will at its option and upon payment of the pro rated service charge set forth below repair or replace the heat exchanger The service charge app
30. On Off Enable RO RJ11 RS 485 Communication Circulator System Supply Water Modbus Network EMS Monitoring Manual Operation Mode and Lost Sensor Blind Mode Application Diagram Showing relevant connections MANUAL OPERATION MODE Features Modulation Hate 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 Sage Boiler Control Instruction Manual 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 th
31. R2 4 11 Introduction Quick Reference CONTROL Outlet Sensor E Outlet Sensor amp Remote Sensor Remote MODE amp Local SP o eS Made Remote SP amp Remote SP Control LCD Display Mode Mode Mode Mode Energy Management System EMS Boiler Control Typical Single Boiler Multiple Boi Hemi Application ingie bolier UITIPIE bOII ers Single Boiler Multiple Boilers Modulation Operation Setpoint Input Setpoint Input Rate Input MEC IA II E E ES piod Boiler Outlet Remote System Boiler Outlet Remote System Input C C Input C4 C EN Hot Water Priority Option Option Ignored Ignored Ignored Ignored DHWP Warm Weather Shutdown Option Option Option Option Option Ignored WWSD Call For Heat II AA A A A OO Based on Based on Based on Based on Input RO or NEN Setpoints Setpoints Setpoints Modbus anua E Rate Control Setpoint Setpoint Setpoint Setpoint d J Lead Boiler Peer to Peer With Peer to With Peer to With Peer to banared anarei Control Connected Peer Connected Peer Connected Peer Connected g g Remote EMS Input C C Manual Ignored Ignored Ignored Ignored By Operator Control g g g g g y By Operator amp o Connections Econ DIC Ignored Ignored Closed Closed Closed Ignored Input LR Remote On Off Enable Eran Enable Enable ucl On Off Ignored Disable Disable Disable Disable Input RO Input C C Setpoint Setpoint Modulation g Peer To Peer Peer To Peer Peer To Peer Peer To Peer Communication Modbus Netw
32. SYSTEM Items provided by this menu are shown on page 43 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 Page 43 of 56 Trouble Shooting Diagnostic Menu Continued o lt Displa Call For Heat OLL Vent Inducer Off Boiler Pump OLT System Pump Off Spare Output OLE Boiler Outlet 0 Boiler Inlet OS Outside Air 05 Remote System 0 Remote Input 0 PCB Temperature 0 Boiler Demand o Mix Valve Demand 05 2 Sage Boiler Control Instruction Manual DISCRETE OUTPUTS These screens provide a convenient way to trouble shoot wiring during the installation phase Each screen provides the status of a controller output These displays show the status of the corresponding Discrete Output ANALOG INPUTS These screens provide a convenient way to trouble shoot wiring during the installation phase Each screen provides the status of a controller analog input These displays show the status of the corresponding Analog Inpu
33. Sage Boiler Control SBC BURNHAM LESS T r Commercial Boilers n st ru ct i on M anua www burnhamcommercialcastiron com Contents Application The Sage Boiler Control SBC has been designed Introduction for commercial hot water boiler applications Quick Reference 2 Overview 4 intent This instruction manual includes detailed functional Product Features installation and setup information Boiler Sequence 6 Single Boiler Control Mode 9 Multiple Boiler Control Mode 10 EMS Boiler Control Mode 11 Manual Boiler Control Mode 14 o Auiliary Device 15 BURNHAM e a a e a a o Front Panel Commercial Boilers Features 16 Display Mode 17 Q Power ALARM Menu Navigation 18 Setpoints Menu 19 Installation Mounting amp Wiring Sensors 20 Terminal Layout 25 External Connections 26 Communication 28 Peer To Peer Network 30 RS485 Modbus Network 31 Setup Tuning C gt Boiler Configuration Menu 33 control system System Configuration Menu 34 Setup Menu 35 Manual Mode 40 Trouble Shooting Sage Boiler Control Front Panel Alarm Messages 41 Showing Power Alarm LEDs Diagnostics Menu 43 2 Line 16 Character Message Display Sensor Resistance Chart 46 and 4 Pushbuttons Security Menu 47 Specifications General 48 Component Description amp Repair Part Numbers 49 Appendix A Parameter Summary 50 B Customer Parameter Worksheet 52 Warranty Rear Cover Sage Boiler Control Instruction Manual Page 1 of 56 102121 01
34. 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 32 of 56 Configuration amp Tuning Boiler Configuration Menu e Boiler operating behavior is adjusted using the configuration amp tuning menus Press and hold the key to leave the Display Mode and access the Main Menu Use the D O keys scroll down to the required Menu and push the D key Factory L2 Setting Range Choices Parameter and Description Deg F s Deg F s foe F Display Units 9 foe C Selects how temperature parameter values are displayed Boiler Pump Activates the boiler pump output according to selected function None None No Boiler Pump On Alwa On Always Pump Runs Continuously None ys Purge Pump Runs during pump pre post purge operations and durin Purge g p g pump pre post purge op g Lead On call for heat E 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 0 to 600 Pump Prepurge 3 15 Sets length of time the boiler pump will be run prior to closing the Call for Seconds Heat relay CH Postpurge Delta 0 to 20 Sets the temperature above boiler inlet temperature that boiler outlet CorF temperature must be below before turning off the boiler pump during pump post purge Pump Cooldown State eee E Yes Ena
35. 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 96 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 Sage Boiler Control Instruction Manual 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 temperat
36. anual No Display Only Outdoor Reset Parameter and Description 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 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 Outdoor Reset Outdoor Set Up The Outdoor Set Up temperature is the outdoor temperature at which the Boiler Set Up temperature is supplied 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 Outdoor Design The Outdoor Design Temperature is the outdoor temperature at which the Boiler Design temperature is supplied Boiler Design The Boiler Design setting is the water temperature required to satisfy the building heat loss during the Outdoor Design temperature If the building feels cool during cold outside conditions the Boiler Design setting should be increased Page 37 of 56 Configuration amp Tuning Setup Menu Continued Slower Response 4 amp 4 Factory Setting gt Faster Response mi Duc uri ur p inute Repeats M inute Repeats M inute E x Faster Response Slower Response
37. bles the mixing valve control output and user display e I coges Yes Enables the return temperature display and control logic ra wo ye year Displays and sets the time and date of the boiler s real time clock Bee Limit MEN 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 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 Off the system pump is operating If output SO is set to S oystem Backup Pump system pump output SO is yS t ump ized and System pump Feedback is de energized Bsadbact energized and System pump nerg rere the System Backup Pump output SO is energized Low Fire When the Fuel Valve Energized input CS is not energized and Input Sl is energized the modulation rate is set to the Low Fire setpoint When input Sl is not energized the modulation rate is set to Fan Purge setpoint When the fuel valve energized input CS is energized input Sl is ignored Spare Output Sets the function of the Spare Output Terminal SO Off Never close output SO CAD Combustion Air Damper CAD or fresh air damper Off Closes SO relay with a call for heat Opens SO relay 2 CAD minutes after call for heat has been de activated S System Pump BU Closes when System Pump ou
38. bus Mode Interface Remote Sensor Control monitors Remote System Temperature a Call For Heat is initiated when 8 Remote SP Remote System Temperature is below the Remote Setpoint Input terminal C C or Mode Modbus Interface Remote Control Control monitors Remote On Off Enable input Terminal RO or Modbus Interface a Mode Call For Heat is initiated when input is energized Manual A Call For Heat is initiated when Manual Mode Menu item Boiler On Off is set to On Operation Mode Control monitors Remote System Temperature a Call For Heat is initiated when Remote System Temperature is below the Operational Setpoint Start Stop Sequence States BOILER STATE LCD Display Pump Purge CONTROL MODE LCD Display Description Once a Call For Heat is initiated and Boiler Pump Purge is selected the pump output Any Mode is energized until the Pump Prepurge Time is complete If the Call For Heat condition Except still exists at the end of the Prepurge Time the temperature of the water at the sensor Manual Mode may rise with boiler water flowing passed it the pump will continue to operate and the Call For Heat Relay is energized Power is applied to the safety limit string If any limits does not pass power is not Limit Hold Any Mode 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 Igni
39. by Burnham Commercial or its representative the parts claimed to be defective and if requested by Burnham Commercial to ship these parts prepaid to Burnham Commercial at the above address for inspection or repair In addition the owner agrees to make all reasonable efforts to settle any disagreement arising in connection with a claim before resorting to legal remedies in the courts THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE Burnham Commercial P O Box 3939 Lancaster PA 17604 Revised November 1 2009 Page 56 of 56
40. cally 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 Ensure the Protocol parameter is set to Peer to Peer Use the Param Code parameter to check that Network Relevant parameters are configured identically refer to page 43 for parameter location
41. d PLANT LOAD BOILERS REQURED Nm 1 Fast Change Load 0 Change Start Start Start Stop Stop Stop Lead Boiler 1 Lag 2 Lag 2 ag 1 Lag Lead Boiler 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 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
42. duct Features Multiple Boiler Control Display Shows Remote Sensor amp Local SP Mode Wired to Each ECM Controller NL Outside Air Temperature O O Boiler Boiler Boiler Circulator O Circulator A Circulator DO Remote System Temperature R R Boiler Outlet p Boiler Inlet Bg B ai cm b Outside Air Temperature Temperature Temperature Remote System BO BC Bl BC O O Temperature RaR PR MEN LU dL Connects to ERES Up to Eight eee o o t X sS LL iim afa Boilers Domestic Hot Water Priorit DHW Override RJ11 RS 485 DP d System lt gt Switch DP Peer to Peer Circulator Ww Network Remote Sensor amp Local SP Mode Application Diagram Showing relevant connections for 3 boilers typical for up to 8 Features Selecting This Control Mode Setpoints To select Remote Sensor Local SP Mode set the 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 9e is above an adjustable High Fire Rate Limit parameter 37 for too long a time Options Outside Air Reset If
43. e 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 Sage Boiler Control Instruction Manual Selecting This Control Mode To select Outlet Sensor amp Local SP Mode set the following parameters System Configuration Menu Remote Control No Remote System Temperature Sensor No Remote On Off Enable Inout 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 Page 9 of 56 Pro
44. e controller has entered Lost Sensor Blind Mode the user may switch the boiler into manual mode or repair replace or reconnect required temperature sensors Page 14 of 56 Product Features Auxiliary Device Control Return Water Standby System Pump Start Stop SO System Pump Feedback SI pee System Supply Water System Pump Start Stop SP EM wu AN Combustion Air SVP Start Stop BP Supply Open Close SO Baleriniet Temperature E ea Eaa EE A alte eaters BI BC Mixing Valve M Control MR MS Boiler Pump Energy Management System EMS Interface Boiler Outlet Temperature BO BC Modbus RS 485 RJ 11 Connection Spare Output VI 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 H20 Delta
45. e 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
46. erature 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 amp 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 Page 11 of 56 Product Features Energy Management System EMS Boiler Control continued Display Shows Remote Sensor 8 Remote SP Mode EMS System Connections Return Water Wired to Each _ Lockout Indicator LO ECM Controller Soft Alarm SO Remote On Off Enable RO Remote Setpoint C C Outside Air Temperature O O Boiler Boiler Boiler Circulator A Circulator CS Circulator CS Remote System Temperature d Y F D 7 gt dd el E rn ne eee i pL E Gudea Temperature Remote System BO BC BI BC O O Temperature R
47. ervicing a Domestic Hot Water Priority DHWP request On Point 0 F to 99 F The boiler starts when the water temperature drops On Point degrees below the setpoint Off Point 72 15 0 F to 99 F The boiler stops when the water temperature rises Off Point degrees above the setpoint High Temp Stop The boiler stops when the boiler outlet water temperature is above the High 73 210 60 F to 230 F Temperature Stop setpoint This setpoint is active in every control mode If the lead boiler s boiler outlet temperature is above the high temperature stop all boilers are stopped DHWP Setpoint The Domestic Hot Water Priority DHWP Setpoint is active when DHWP Input 74 180 140 F to 230 F DP closes and DHWP parameter is set to yes and Local SP Mode is selected When the contact is closed the boiler outlet is maintained at or above the DHW Setpoint WWSD Setpoint 75 DES 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 Max SP A E The Maximum Operational Setpoint for all possible Local and Remote modes Min SP 60 F to 230 F The Minimum Operational Setpoint is the lower limit for all Local and Remote modes Min BIT com bbs id Low Boiler Inlet Temperature alarm and event setpoint Min In H20 Temp 110 F to 180 F Minimum Inlet Water Temperature setpoint used as the Mixing Valve inlet tem
48. es 1 2 Used Only For Peer To Peer Network When using Modbus Network wire Outside Air and Remote System sensor to only one boiler 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 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 amp R terminals to daisy chain the boilers together eliminating the need for RJ45 cables and splitters and reducing the loop impedance Sage Boiler Control Instruction Manual Page 27 of 56 Installation Communication The Peer To Peer or Modbus networks allow boiler information including modulation rate and on off commands to be sent via a standard phone cable thus avoiding the cost time and complexity of wiring multiple signals Connects to Up to 8 Boilers Or Building Automation System BAS Modbus OOOO Sage Control OOOO Sage Control Sa
49. evel at is 86 power up Sage Boiler Control Instruction Manual Page 47 of 56 Specifications General Mechanical Panel Assembly 8 inches wide x 6 inches tall Message Display 2 x 16 Character 8 06 mm characters Environmental Operating Temp 32 to 140 F 0 to 60 C Storage Temp 20 to 150 F 28 to 65 C Humidity Limits 15 to 95 non condensing Front Panel NEMA 1 Electrical Power Supply 24Vac Note All 24Vac Inputs must be connected to the same phase as PR Internal Power Consumption 8 VA max 24Vac 15 and 6 VA max 12Vac 0 5A for LO VI BP SP and SO Discrete Inputs DP Domestic Hot Water Priority DHWP 12Vdc 1mA RO OO BumerOn Offwich 24Vac 1imA Low Combustion Air Flow Discrete Outputs BP jJBolrPump gt gt A 12Vdc 100m Analog Inputs BO Boiler Outlet Water Temperature 10k Thermister 5Vdc 5 mA max load BI Boiler Inlet Water Temperature 10k Thermister 5Vdc 5 mA max load Outside Air Temperature 10k Thermister 5Vdc 5 mA max load Remote System Temperature 10k Thermister 5Vdc 5 mA max load C4 0 10 Vdc 100K ohm impedance Remote Modulation Rate or Remote Setpoint 1Vdc 0 9Vdc 100 Analog Outputs 0 100 Duty Cycle OV Off 10V On P Modulation Rate Output to Mod Motor 0 10 V 5 mA max V MR 4 mA 0 96 Open 20 mA 100 Open Sage Boiler Control Instruction Manual Page 48
50. ext 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 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 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 Page 16 of 56 Front Panel Display Mode All values shown in Display Mode are for display only and can not be adjusted by the operator The O O keys scroll through the Display Mode screens Boiler State 1 Alarm Message Standby Low Inlet Temp OUT IN OUT 189F IN 180F RST RST 189F OA 180F OA OUT or RST OUT 189F SP 1S9Q0F SP MOD RATE SH 100 MOD RATE SH DH In In 180F SP 130F SP MIX VALVE 1005 MIX VALVE Control Mode Outlet Sensor amp Local SP Mode Cycles CYCLES HOURS y ata AA Hours Home Screen Standby boiler state shown refer to the top of page 6 amp 7 for explanation of each boiler state 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 ac
51. ff Switch Of On 2 0008 LowWaterFlow Of On 2 00009 High and Low Gas Pressure Switches Of On 2 00010 Operating or High Limit Of On 2 00011 Low Combustion Air low Of On 2 00012 Fuel Valve Energized 1 Of On 00013 Flame Safeguard Alarm Of On 00014 Call For Heat CF Of On 0005 GeneralAlarm Of On 4 0006 Venlduer 3 Of On 0007 BolrPum Of On 0008 SytemPum Of On 00019 Spare Output Programmable Of On 00020 State Boiler Disabled Of On fjs 00021 State Weather Shutdown A Of On 3 00022 State Lockout 1 Of On 3 000983 StatePumpPuge Of On hB 00024 StateLimitHold J 1 Of On 3 00025 StaePugePiltlom Of On fhs 00026 State Low Fire lgniton Of On fs 00027 State Main Ignition J Of On 3 00028 State Low Fire Hod J A off On fh 00029 State Boiler Running Of On 3 00080 StateFanPostPurge Of On 3 00031 State Pump Cool Down 1 Of On fh 00082 StateStandy ort On 3 00083 AnnunciatorLowWaterLevel On f4 00034 Annunciator Off Switch J off On 4 00085 AnnunciatorLow Water Flow
52. ge Control l l Connection Boiler 1 Boiler 2 Boiler 3 RJ11 Splitter RJ11 Splitter Not Included Not Included Multiple Boiler RJ11 Connection Diagram OOOO Sage Control OOOO Sage Control Boiler 1 Boiler 2 Two Boiler RJ11 Connection Diagram When Wiring Modbus Communication to a Building Automation System BAS The Modbus communication connects to the same RJ11 port that is used by the peer to 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 Slot Connection Color Number Red 2 JB Green 3 BO 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
53. ge 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 96 when the linkage is at rated boiler output 0 to 100 Please Note Full Scale 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 10096 FR that value should be entered in parameter 49 as blower speed high This will establish the correct scaling factor and will prevent overfiring of the boiler Blower Spd Low Linkage Min Position O to 100 Percent 0 10 Vdc output V V or pulse output that represents a 0 Full Scale modulation rate This scaling factor allows the Sage Boiler Control to display 0 when the linkage is at minimum boiler output Low Fire Spd Modulation 96 used for Low Fire Hold and Low Fire Start conditions Low Modulation Rate fire position is established by the linkage adjustment This parameter may be left at 0 Fan Purge Speed 0 to 100 Note Fan Purge Speed used during Low Fire Hold parameter 53 e Modulation Rate Burners with linkage control purge and light off rates using the RM7800 and linkage adjustments Low Fire Hold 10 to 1200 Time modulation rate is held at preset value Low Fire Spd or Fan Purge Seconds Spd depending on the
54. 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 Sage Boiler Control Instruction Manual 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 amp 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 Page 13 of 56 Product Features Manual Boiler Control Mode Display Shows Manual Operation Mode and Lost Sensor Blind Mode Return Water Boiler Circulator Boiler Outlet gt Temperature BO BC System Boiler Inlet l d Lockout Indicator LO Soft Alarm SO Remote
55. ir temperature sensor with weather proof box and protective sleeve For use in outdoor reset applications 5 Wire Harness Saget O7 S00 d tapete hi troi tae eee poem s te tameo sti eom as 101976 01 6 O7800H Flame ateguard SUD 356 it AE A AA 101182 01 Te Sage Control Programmed ui ios 102436 01 8 SBC Parts Carton MPC includes MPC Sensor J Box Snap bushing for Sensor J Box and MPG Sensor J BOX GOVer With Holes sco otto id 101977 01 Sage Boiler Control Instruction Manual Page 49 of 56 Appendix A Parameter Summary Network E Factory Security Boiler Configuration Menu Display Units InletSemsor_ Yes No Sd Yes Superisor Mixingvawe Ves No No Supervisor 31 Update Set Time Date hour minute month day year Basic 31 Off Sys Pump Feedback Low Fire System Configuration Menu Off Isolated Demand Shared Demand FREE S URP Yes Remote control Hemote Mod Modbus Mod No Supervisor hRemoteivots 60FtotB0F 140 Supervisor 32 Remote9vots A 150Fto230F amp 220 Superviso 32 Update AlarmMessage 1 LowWaterlevel Supervisor 32 Setup Menu P bli i ae Ja Yes WWSD Pump Both Off Basic 33 501010096 of Modulation Rate 90 Supervisor 33 0 to 5096 of Modulation Rate Supervisor Boiler Design 80 F to 220 F 180 Parameters identified by Yes under the Network Relevant column must be configured identically on all
56. lded cable ii Trim the shielded cable s silver drain wire so that it will not come in contact with any metal surfaces within the J box The drain wire is not used at this end of the cable Sage Boiler Control Instruction Manual Page 20 of 56 j 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 Mount the sensor J box cover to the right rear panel using two 2 of the 8 x 7 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 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 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 cab
57. le 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 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 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 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 e
58. lectrical 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 lil 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 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 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
59. let Temperature Ems System Hardwired Connections Lockout Indicator LO Soft Alarm SO Remote On Off Enable RO Remote Setpoint C C RJ11 RS 485 Communication Outside Air Temperature Boiler O O Circulator Boiler Outlet gt N Temperature 5 DHW EM Ovemos Switch DP System Domestic Hot 7 y Water Water DHW pply Supply Peer To Peer Network for Modulating Lead Lag Or Modbus Network _for Touch Screen or EMS Monitoring Outlet Sensor amp 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 Sage Boiler Control Instruction Manual Selecting This Control Mode To select Outlet Sensor amp Remote SP Mode set the following parameters System Configuration Menu Remote Control Remote SP Remote System Temp
60. licable to a heat exchanger warranty claim is based upon the number of years the heat exchanger has been in service and will be determined as a percentage of the retail price of the heat exchanger model involved at the time the warranty claim is made as follows Service Charge as a 96 of Retail Price YearsinSevcel 1 2 3 4 5 6 7 8 9 10 No Charge Stainless Steel No Charge 20 40 60 80 100 NOTE If the heat exchanger involved is no longer available due to product obsolescence or redesign the value used to establish the retail price will be the published price as set forth in Burnham Commercial Repair Parts Pricing where the heat exchanger last appeared or the current retail price of the then nearest equivalent heat exchanger whichever is greater ADDITIONAL TERMS AND CONDITIONS 1 Applicability The limited warranties set forth above are extended only to the original owner at the original place of installation within the United States and Canada These warranties are applicable only to boilers parts or accessories designated as commercial grade by Burnham Commercial and installed and used exclusively for purposes of commercial space heating or domestic hot water generation through a heat exchanger or a combination for such purposes and do not apply to residential grade products or industrial uses 2 Components Manufactured by Others Upon expiration of the one year limited warranty on commercial grade boilers all b
61. ng the next boiler Long time delay to avoid temperature going below setpoint as a result of a slow process change FR Off Delay 36 20 1 to 30 Time Delay after the modulation rate is below the LL Stop Trigger before Minutes stopping the next boiler Long time delay to avoid temperature going above setpoint as a result of a slow process change High Fire Limit To maximize high efficiency condensing operation the firing rate is limited to an adjustable value The Sage Boiler Control will keep the boilers at this firing rate or lower as long as the boilers will handle the load After the last boiler has started the modulation rate is released up to 100 Modulation Rate Deg Min Hold Off Specifies a temperature rate of change that inhibits the next boiler being started or stopped If the temperature is increasing faster than this rate of change the next boiler is not started Also if the temperature is decreasing faster than this rate of change the next boiler is not stopped Cutback Setpoint Boiler Outlet temperature above the Cutback Setpoint causes the 39 220 100 240 modulation rate to be reduced proportionally to help avoid a high Cor F 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 Degrees Minute Sage Boiler Control Instruction Manual Page 35 of 56 Configuration amp Tuning
62. ntified 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 B Customer Parameter Worksheet Range Choices Boiler Configuration Menu Circle one DegF DegC NEN Boiler Pump Circleone None OnAlways Purge Onlead PumpPrpuge Seconds Postpurge Delta S O System Configuration Menu DHWP Circle one Off Isolated Demand Shared Demand unm _ oe EE Circle one No Remote SP Modbus SP mE Remote Mod Modbus Mod Remotetvolts Remote9volts J o OO A Remote Sensor Circle one No Display Only Control ST System Pump Circleone Yes No LWCorCAD Circleone Yes No Z o Alarm Message AS Seconds Setup Menu WWSD LL Start Trigger YA LL Stop Trigger O Boiler On Delay J Seconds Boiler Off Delay J Seconds High Fire Limit A Rotation Circleone Enable Disable Rotation After Oo A NE 200 A oo O FE ASAS
63. o field 32 F 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 Actual OAT EM Remote System Temperature RST Outside Air Temperature OAT Boiler Outlet Temperature BOT Boiler Inlet Temperature BIT Actual BOT Calibration Procedure 32 F 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 Actual BIT 30 F applied Parameter Code This number represents Network Relevant parameters It can be used to Param Code ensure that these parameters are identical when establishing a Peer To Peer network Sage Boiler Control Instruction Manual Page 45 of 56 Trouble Shooting Sensor Resistance Chart Sensor Temperature vs Resistance Ohms of C F Resistance e E 231 6 103488 16 60 15313 52 126 3311 96 999 17 62 14546 53 128 3176 90 962 18 64 13 822 73 164 1 565 18 O 85340 19 66 13 139 74 166 1 508 80 103 88 Hm e 8 Lm 75222 21 70 11884 77 170 1401 70 670 2
64. 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 programmeod cooooocncnniconnnccccccnncnonnnonnnnnncnnnnnnnnnnnnooonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnns 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 Temperatur Sensor ti a 101935 01 Yo NPT 10K OHM 25C NTC Thermistor Type Resistance Ratio RO R50 9 07 temperature sensor for measuring water temperature in supply manifold return manifold or system header A Outdoor Temperature Senso s cte cione A uid uu eu usu eu eR uU dope da 801SOL0012 10K OHM 25C NTC Thermistor Type Resistance Ratio RO R50 9 07 outdoor a
65. 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 21 of 56 Installation Mounting amp Wiring Sensors Cont SUPPLY MANIFOLD SNAP BUSHING 1 2 SBC SE TEMPERATURE y 3 A J SENSOR SENSORS Y LN f BOX E A 2 J d y o he r h CERE e 4 Eum 4 z SENSOR BOX COVER WITH HOLES Figure 1 Installation of SBC Components Part 1 Sage Boiler Control Instruction Manual Page 22 of 56 Installation Mounting amp Wiring Sensors Cont SENSOR J BOX COVER WITH HOLES RETUR MANIFOLD Figure 2 Installation of SBC Components Part 2 Sage Boiler Control Instruction Manual Page 23 of 56 Installation Mounting amp Wiring Sensors Cont V9 V11 Boilers 1 Mount Boiler Inlet and Outlet Water Temperature Sensors a Remove one of the Y immersion temperature sensors from the Sage Boiler Control Parts Carton and apply thread sealant to the threads between the probe and hex shoulder Install the supply sensor in the 3 4 tapping T or J V9 V11 respectfully using a 34 x 77 bushing Refer to Figure 3
66. oiler components other than heat exchangers manufactured by others but furnished by Burnham Commercial such as oil burner circulator and controls will be subject only to the manufacturer s warranty if any 3 Proper Installation The warranties extended by Burnham Commercial are conditioned upon the installation of the commercial grade boiler parts and accessories in strict compliance with Burnham Commercial installation instructions Burnham Commercial specifically disclaims liability of any kind caused by or relating to improper installation 4 Proper Use and Maintenance The warranties extended by Burnham Commercial conditioned upon the use of the commercial grade boiler parts and accessories for its intended purposes and its maintenance accordance with Burnham Commercial recommendations and hydronics industry standards For proper installation use and maintenance see all applicable sections of the Installation and Operating and Service Instructions Manual furnished with the unit 5 This warranty does not cover the following a Expenses for removal or reinstallation The owner will be responsible for the cost of removing and reinstalling the alleged defective part or its replacement and all labor and material connected therewith and transportation to and from Burnham Commercial b Components that are part of the heating system but were not furnished by Burnham Commercial as part of the commercial boiler c Improper burner adjus
67. ol Modes Refer to Local PID P for explanation O to 10000 Integral Gain value for Remote System Temperature sensor control Modes Refer to Local PID for explanation O to 10000 Derivative Gain value for Remote System Temperature sensor control Modes Refer to Local PID D for explanation Sage Boiler Control Instruction Manual Page 38 of 56 Configuration amp Tuning Setup Menu Continued Factory a Setting ange Cholces Parameter and Description Mixing Valve P Proportional Gain value for boiler Inlet temperature sensor control mode A larger gain value results in tighter more active PID control Gain is the 0 to 10000 primary PID modulation rate tuning adjustment and provides the immediate mixing valve modulation response Pick a gain based on the desired initial resoonse The mixing valve can oscillate if the Proportional Gain is too large Mixing Valve I Integral gain value for boiler inlet temperature sensor control mode A smaller value makes the Integral ramp in less time i e faster Integral is a secondary PID modulation rate tuning adjustment that ramps the output 0 to 10000 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 15 40 Mixing Valve D The Derivative gain value for boiler inlet temperature sensor control mode O to 10000 A larger Derivative gain val
68. onfiguration amp Tuning Setup Menu E E a E E Range Choices Parameter and Description WWSD Off WWSD of Boiler WWSD of Sys Pump Both 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 50 to 100 LL Start Trigger Maximum Specifies the percent of maximum modulation rate the running boiler s Modulation Rate must reach before calling upon additional boilers for help 0 to 50 LL Stop Trigger 32 10 Specifies the modulation rate that the running boiler s must be below Modulation Rate before shutting down a lag boiler Boiler On Delay 60 to 900 Time Delay after On Point setpoint has been reached before starting the Seconds next boiler Short time delay to prevent nuisance starts due to momentary temperature and modulation rate swings Boiler Off Delay 0 to 900 Time Delay after the Off Point setpoint before stopping the next boiler Seconds Short time delay to prevent nuisance stops due to momentary temperature and modulation rate swings FR On Delay 35 20 1 to 30 Time Delay after the modulation rate is above the LL Start Trigger before Minutes starti
69. ork o i i Onl Modbus Modbus Modbus Modbus y Additional Page 10 Page 11 Page 12 Page 13 Page 14 f Modbus is selected the Peer To Peer Network can not be used Modulating Lead Lag features require the Peer To Peer Network Modbus Only Sage Boiler Control Instruction Manual Page 2 of 56 Introduction Quick Reference Abbreviation List AL BIT BOT SBC EMS GP High LimitAquastat 1 1 BV C CA CH CS DH High Limit Aquastat HP LL Lead Lag LO M Mix OA OL OUT RST SH Setpoint As found in Operational SP and Remote SP Termination Number Identification Typical AL BT BOT BA p BY C CA CH _ CS DH DP SBC EMS _ Lo NEN NNI MEN NE LO A E Mx OA OL O00 OUT RO RST _ SH Description E Mixing Valve Control MR MS Termination Numbers Sage Boiler Control Instruction Manual Page 3 of 56 Introduction Overview Sage Boiler Control Overview The Sage Boiler Control SBC is a complete boiler monitoring and automation system The SBC provides advanced boiler modulation operating control diagnostics multiple boiler lead lag and auxiliary device control The SBC 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 ar
70. orth herein These warranties are given in lieu of all other express warranties ALL APPLICABLE IMPLIED WARRANTIES IF ANY INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE YEAR EXCEPT THAT IMPLIED WARRANTIES IF ANY APPLICABLE TO THE HEAT EXCHANGER IN A COMMERCIAL GRADE BOILER SHALL EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE OF INSTALLATION SOME STATES DO NOT ALLOW LIMITATION ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU PROCEDURE FOR OBTAINING WARRANTY SERVICE In order to assure prompt warranty service the owner is requested to complete and mail the Warranty Card provided with the product or register product online at www burnhamcommercialcastiron com within ten days after the installation of the boiler although failure to comply with this request will not void the owner s rights under these warranties Upon discovery of a condition believed to be related to a defect in material or workmanship covered by these warranties the owner should notify the installer who will in turn notify the distributor If this action is not possible or does not produce a prompt response the owner should write to Burnham Commercial P O Box 3939 Lancaster PA 17604 giving full particulars in support of the claim The owner is required to make available for inspection
71. ot mount sensor near exhaust of any kind as this may affect readings Sage Boiler Control Instruction Manual Page 26 of 56 Installation External Connections Continued Outside Air and Remote System Temperature Sensor RJ45 Connection All boilers may be connected to the remote system temperature RST and the outdoor air temperature OAT sensors Only one of each type sensor is needed for connections with up to eight boilers The lead boiler is automatically enabled to monitor the sensors As the boiler lead rotates the sensor monitoring is automatically transferred to the new lead boiler Boiler 2 Boiler 1 O b d b oPower Alarm E oPowero Alarm BOILER RUNNING z BOILER RUNNING e gt 6 SoA Outside Air E Temperature OOOO E OOOO i a 5 uz System e R Temperature A x E Connects to lt Up to 8 Boilers Multiple Boiler Connection Diagram Using the extra O O R amp R terminals to daisy chain the boilers together Boiler 2 Boiler 1 O b D y Y y e tc oPower Alarm Power Alarm BOILER RUNNING BOILER RUNNING E Outside Air Temperature O00 OOOO emo oS oa System Temperature ho P d Two Boiler RJ45 Connection Diagram Refer to Note 2 Not
72. perature setpoint Max H20 Delta T 20 F to 50 F Maximum Water Differential Boiler Outlet minus Boiler Inlet Temperature setpoint used as the Mixing Valve differential temperature setpoint Max Delta T Hold 81 40 20 F to 50 F Maximum Water Differential Boiler Outlet minus Boiler Inlet Temperature used to hold modulation rate at low fire Only visible when parameter enabled on the configuration and setup menus Sage Boiler Control Instruction Manual Page 19 of 56 Installation Mounting amp 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 Y immersion temperature sensors from the Sage Boiler Control Parts Carton and apply thread sealant to the threads between the probe and hex shoulder Install the sensor in the 1 2 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
73. ss The boiler address assignment determines the boiler sequencing order A value of O disables the network communications Only visible when Protocol equals Peer to Peer Online Status Each space can be either the boiler address or a depending on whether there is a boiler of that address on line Only visible when Protocol equals Peer to Peer Example 6 321 indicates that boilers 6 3 2 and 1 are online Sage Boiler Control Instruction Manual Page 29 of 56 Installation Peer To Peer Network The Sage Boiler Control includes a dependable Peer To Peer communication network This network allows multiple boiler modulating lead lag control and status signals to be transferred between boilers In order to successful use this network certain requirements must be followed Network Relevant amp 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 identi
74. t 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 Page 44 of 56 Trouble Shooting Diagnostic Menu Continued System Menu Display Software Revision Software Rev S 3 24 Displays current Software Revision PCB Temperature PCB Board Temperature id The operating range for the control is 32 to 140 F Clear Boiler Inlet Temperature BIT Memory Clr BIT Hist No Action History remains unchanged No Action Yes Clears low BIT memory Clear Alarm History Memory Clr Alarm Hist No Action History Remains unchanged No Action Yes Clears alarms memory Clear Boiler Run Time Hour Accumulator Memory Clr Run Time Cnt Boiler Run Time Hours are displayed in Display Mode as Hours No Action 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 No Action Hours Remain unchanged Yes Clears accumulated cycles memory Clear User Installed Parameter Memory Factory Defaults No Action Currently set parameter values are unchanged No Action Set Sets all parameters back to their Factory Default values Temperature Input Fine Calibration Actual RST All inputs are factory calibrated However it may become necessary t
75. ted or is reading above or below a valid range If Remote System O Red Alarm Temperature Sensor mode was selected the control will transfer to Boiler Light Outlet Sensor Mode Sage Boiler Control Instruction Manual Page 41 of 56 Trouble Shooting Alarm Messages continued LCD Display Recommended Action Explanation Alarm Message Remote Input Check wiring and Remote Control Input Fail Fail Remote System 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 amp Remote Sensor Remote Sensor and Local Setpoint O Red Alarm Remote SP Outlet Sensor and Local Setpoint Light Remote SP amp Remote Sensor Remote Sensor and Local Setpoint Comm Failure Check wiring and Communication Failure Remote System The Modbus or Peer To Peer network has failed When the Modbus network fails the following control mode changes are taken Confirm each boiler has automatically a unique address Selected Modes Resulting Control Mode Modbus Mod Outlet sensor and Local Setpoint Modbus Mod amp 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 un
76. the boiler start stop status when in Manual Mode Vanes On No Turn off boiler if running otherwise remain off Off Yes Turn on boiler if off otherwise remain on Activated only when in Supervisor Mode and Boiler Man Auto Man Mixing Valve M A Mah Man Remain in Manual Mode A i Ma Auto Auto Return to Control Mode specified by parameter boiler conditions Activated only when in Supervisor Mode Mixing Valve Sets the Mixing Valve Open to be used for valve when in Manual Mode Varies O to 100 Activated only when in Supervisor Mode and Mixing Valve M A equals Man LS Sage Boiler Control Instruction Manual Page 40 of 56 Trouble Shooting Alarm Messages Alarm Messages are shown one at a time in priority order The message closest to the top of this List is displayed first Following messages are not shown until the higher priority message has cleared All alarm messages are also stored in the Fault History LCD Display Explanation Alarm Message Action Low Water Level Manually Resetthe Low Water Cutoff Switch Low Water Cutoff 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 O Flashing Red LC does not receive power and the Call For Heat output CH is powered Alarm Light the Low Water Level Message is displayed Off Switch Turn Burner Switch Burner Switch is Off On Control switch is in the OFF position and is preventing the
77. the snap bushing facing upward to the inside surface of the right split rear panel using two 2 of the 8 x 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 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 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 shie
78. til 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 O Red Alarm network with at least one other boiler power is cycled or the protocol Light parameter is changed to Modbus and then back to Peer To Peer Low Inlet Temp Check wiring and Low Boiler Inlet Temperature sensor If the boiler inlet temperature is below the Low boiler inlet temperature setpoint the Low Inlet Temp Message is displayed and the boiler inlet Check return water temperature history is stored See following page for additional temperature Consider information on Low boiler inlet temperature history storage and retrieval system or operational O Red Alarm changes to avoid low Light temperature events Memory Failure Call Factory Memory Failure Reset all memories in New software has been installed in the Sage Boiler Control or a power System menu interruption has caused a memory failure The Call For Heat will be Clr BIT History prevented until the condition is cleared Clr Alarm Hist Clr Run
79. tion After the limit string passes power the fan is started the modulation output is set to ETE ETE Purge Rate When the purge period is complete the flame safeguard sequences on the ignition transformer and pilot Low Fire When the Spare Input Low Fire is selected modulation output is set to the Low Fire Ignition y opeed when the Spare Input is energized Main Ignition The main gas valve input is energized and the modulation output is held constant for Any Mode an ignition stabilization period po Any Mode The modulation output is held at the Low Fire for the Low Fire Hold time Boiler When this Low Fire Hold time is complete the modulation output is released to Any Mode Running modulate Fan Post Purge When water temperature is above setpoint there is a Flame Safeguard or Limit fault Any Mode the Call For Heat is ended and the modulating output is set to Purge Rate for the Post Purge Time En When Boiler Pump Purge is selected the boiler pump remains on until the boiler P Any Mode outlet temperature is less than the Post Purge Delta default is 5 F above the Boiler Cooldown Inlet Temperature Sage Boiler Control Instruction Manual Page 7 of 56 Product Features Boiler Sequence Continued Multiple Boilers 00 al Lu or P Setpoint A 180 m gt a m E High Fire Limit 100 Parameter 37 Lu C C HE 50 0 OZ Or LL 0 Sage Boiler Control Instruction Manual Slow Loa
80. tive Boiler Outlet Temperature Boiler Inlet Temperature Remote System Temperature visible when Remote Sensor Display Only or Control Outside Air Temperature visible when Outdoor Sensor Display Only or Outdoor Reset Boiler Outlet or Remote System Temperature Remote System when Remote Sensor Control Active Setpoint Modulation Rate Space Heating active when DH is not Domestic Hot Water Priority visible when DHWP Yes and DP input is true Boiler Inlet Temperature Min In H2O Temp Modulation Rate Outlet Sensor amp Local SP Mode message shown refer to page 2 for an overview of each control mode 0 8 Lead Boiler when zero is displayed modulating lead lag functions are not available Number of boiler cycles Number of boilers operating hours 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 17 of 56 Front Panel Display Navigation Press and hold the we key to leave the Display Mode and access the Main Menu Main Menu DISPLAY MODE BOILER CONF
81. tment control settings care or maintenance d This warranty cannot be considered as a guarantee of workmanship of an installer connected with the installation of the Burnham Commercial boiler or as imposing on Burnham Commercial liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation which liability is expressly disclaimed Pub No BCL1109041 e Boilers parts or accessories installed outside the 48 contiguous United States the State of Alaska and Canada f Damage to the boiler and or property due to installation or operation of the boiler that is not in accordance with the boiler installation and operating instruction manual g Any damage or failure of the boiler resulting from hard water scale buildup or corrosion the heat exchanger h Any damage caused by improper fuels fuel additives or contaminated combustion air that may cause fireside corrosion and or clogging of the burner or heat exchanger i Any damage resulting from combustion air contaminated with particulate which cause clogging of the burner or combustion chamber including but not limited to sheetrock or plasterboard particles dirt and dust particulate j Any damage defects or malfunctions resulting from improper operation maintenance misuse abuse accident negligence including but not limited to operation with insufficient water flow improper water level improper water chemistry or damage from freezing
82. tput is activated but the jump ee System Pump Feedback indicates the Primary Syst Soft Alarm ystem 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 Sage Boiler Control Instruction Manual Page 33 of 56 Configuration amp Tuning System Configuration Menu Factory No Setting Range Choices Off Isolated Demand Shared Demand Remote SP Modbus SP Remote Mod Modbus Mod Display Only Control Characters Sage Boiler Control Instruction Manual Parameter and Description 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 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
83. ue produces a larger PID output contribution proportional to the rate of change of the error Setpoint Boiler Inlet Temperature When set equal to zero it has no effect on the output Max Delta T P 15 0 to 10000 Proportional Gain value for boiler differential boiler outlet minus inlet temperature sensor temperature control mode Refer to Local PID P for explanation Max Delta T I 40 0t Integral Gain value for boiler differential boiler outlet minus inlet o 10000 temperature sensor temperature control mode Refer to Local PID for explanation Max Delta T D 0 to 10000 Derivative Gain Term for boiler differential boiler outlet minus inlet temperature sensor temperature control mode Refer to Local PID D for explanation Sage Boiler Control Instruction Manual Page 39 of 56 Configuration amp 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 Factory i m Setting Range Choices Parameter and Description Boiler Man Auto Man Man Remain in Manual Mode p i Auto AUS Auto Return to Boiler Mode specified by parameter boiler conditions Activated only when in Supervisor Mode vem omo Vari Sets the modulation rate to be used for boiler when in Manual Mode aries O to 100 Activated only when in Supervisor Mode and Boiler Man Auto Man Boiler On Off Sets
84. ure 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 Lead On 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 otandby 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 Page 15 of 56 Front Panel Features Sage Boiler Control Instruction Manual POWER LED Steady On Green LED indicates power is available down ALARM LED SCREEN ENTER UP DOWN MENU stream of the Sage Boiler Control s on board fuse Flashing On Green LED indicates manual mode operation for boiler modulation 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 2 line by 16 character display provides operational alarm sequence status configuration and diagnostic user interface 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 t
85. w Air Flow Message is displayed FSG Fault Manually Reset Flame Safeguard Fault Required Refer to The Flame Safeguard is preventing a boiler start If terminal AL receives Flame Safeguard power at any time the Flame Failure Message is displayed O Flashing Red Manual corrective Alarm Light actions Outlet Temp Fail Check wiring and Boiler Outlet Temperature Sensor Fail sensor 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 O Red Alarm Sensor mode was selected the control will transfer to Lost Sensor Blind Light Mode Inlet Temp Fail Check wiring and Boiler Inlet Temperature Sensor Fail sensor 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 O Red Alarm output will drive to 0 and low temperature alarm and maximum water Light differential boiler outlet minus boiler inlet temperature hold are disabled OA Temp Fail Check wiring and Outside Air Temperature Sensor Fail sensor 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 O Red Alarm weather shutdown WWSD and outside air reset control logics are Light disabled Remote Temp Check wiring and Remote System Temperature Sensor Fail Fail sensor The remote system temperature sensor is configured and is not connec
86. yes and WWSD is set to either WWSD of Boiler or Off Boiler pump is On during Prepurge and Post Purge when Boiler Pump is set to Purge or boiler is lead amp Boiler Pump is set to On Lead Combustion Air Damper Spare Output is maintained On for 2 minutes after the Call For Heat is removed Modulation rate is held at purge when low fire input is not provided gt ooo Sage Boiler Control Instruction Manual Page 6 of 56 Product Features Boiler Sequence Continued Pre Sequence States BOILER STATE LCD Display Boiler Disabled Warm Weather Shutdown Lockout Standby CONTROL MODE Any Mode Except for Remote Control Any Mode Except for Manual Mode Any Mode Boiler is prevented from starting Remote On Off Enable Terminal RO Input is not energized Boiler is prevented from starting Warm Weather Shutdown WWSD is enabled and outside air temperature is above the WWSD Setpoint Boiler is prevented from starting Flame Safeguard lockout is present A Flame Safeguard manual reset is required Outlet Sensor amp Control monitors boiler outlet temperature a Call For Heat is initiated when boiler Local SP Mode outlet temperature is below the Operational Setpoint Remote Sensor amp Local SP Mode Outlet Sensor amp Control monitors boiler outlet temperature a Call For Heat is initiated when boiler Remote SP outlet temperature is below the Remote Setpoint Input Terminal C C or Mod

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