CleaverBrooks Hawk 1000 Operation Manual

Hawk 1000

Boiler Control

Operation Manual

750-366
07/2013

TO: Owners, Operators and/or Maintenance Personnel

This operating manual presents information that will help to properly operate and care for the equipment. Study its con­tents carefully. The unit will provide good service and continued operation if proper operating and maintenance instruc­tions are followed. No attempt should be made to operate the unit until the principles of operation and all of the
components are thoroughly understood.

It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who
are servicing, repairing, or operating the equipment, in all safety aspects.

Cleaver
and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however,
proper operating techniques and maintenance procedures must be followed at all times.

Any "automatic" features included in the design do not relieve the attendant of any responsibility. Such features merely
free him of certain repetitive chores and give him more time to devote to the proper upk

It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instruc­tions can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of
the responsibility for proper operation. On the other hand, a thorough understanding of this manual is required before
attempting to operate, maintain, service, or repair this equipment.

Operating controls will normally function for long periods of time and we have found that some operators become lax in
their daily or monthly testing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to
uneconomical operation and damage and, in most cases, these conditions can be traced directly to carelessness and
deficiencies in testing and maintenance.

The operation of this equipment by the owner and his operating personnel must comply with all requirements or regula­tions of his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency
between such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before pro­ceeding.

-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical

eep of equipment.

Cleaver-Brooks

HAWK 1000

Boiler Control

Operation Manual

Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative

Manual Part No. 750-366
07/2013

CONTENTS

Section 1

General

Introduction .................................................................................. 1-2

System Description ........................................................................

Hawk 1000 System Features .......................................................... 1-4

Safety Provisions and Diagnostics .................................................... 1-5

Inputs and Outputs ......................................................................... 1-6

Section 2

System Components

Overview ...................................................................................... 2-2

Controller ......................................................................................

Human-Machine Interface (HMI) .....................................................2-3

Communications ............................................................................2-4

Sensor Inputs ................................................................................ 2-6

Section 3

Hardware Checkout

Control Panel Component Checks .................................................... 3-2

Modbus Actuator Checks ................................................................3-7

Section 4

System Configuration

Introduction .................................................................................4-2

Main Menu

Boiler Overview ............................................................................4-3

System Configuration ....................................................................4-4

..................................................................................

1-3

2-2

4-2

Section 5

Commissioning

Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Setting Combustion - P

Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . 5-8

Setting Combustion - Low/High/Low. . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Alarms and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Drive Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Two Boiler Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Thermal Shock Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Diagnostics and T

System Monitoring and Diagnostics

PLC Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Hawk 1000 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

ositioning . . . . . . . . . . . . . . . . . . . . . 5-4

arallel P

Section 6

roubleshooting

. . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Section 7

Parts

Section 1

General

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Hawk 1000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Safety Provisions and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Burner Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

www.cleaverbrooks.com

Section 1 — General Hawk 1000

1.1 Introduction

The Cleaver-Brooks HAWK 1000 is an exclusive Boiler Management and Control system specifically designed
to integrate the functions of a Programmable Boiler Controller and Burner Management Controller, as well as
other boiler operating and ancillary controls. The HAWK 1000 system incorporates a user-friendly, graphical
Human Machine Interface (HMI) that displays boiler parameters, fault annunciation and alarm history, as well
as providing access to boiler configuration and control functions.

Figure 1-1. Boiler Overview Screen

Figure 1-2. Typical Panel Layout

1-2 Part No. 750-366

Hawk 1000 Section 1 — General

1.2 System Description

The HAWK 1000 Boiler Control System provides boiler firing rate control to maintain steam pressure (or hot
water supply temperature) on set point. Final control element(s) are modulated via Modbus communications
network to insure that the optimum fuel/ air ratio is maintained throughout the firing range.

The Hawk 1000 supports two fuel types. Each fuel type can be fired in one of three possible methods: single­point combustion, parallel combustion, and LOW-HIGH-LOW (fuel 2 only). In parallel systems, the Hawk
1000 can also control a flue gas recirculation (FGR) damper.

The Hawk 1000 can be monitored by Building/ Plant Automation Systems via an optional CB-PT protocol
translator. EtherNet/ Internet communication also enables remote monitoring of the Hawk 1000 Boiler Control
System. (Additional software and/or hardware required).

The HAWK 1000 may be used on most types of steam and hot water boilers, including firetube, industrial
watertube, and commercial watertube. In addition to installation on new boilers, the HAWK 1000 can be
added as a retrofit to existing boilers. Call your local authorized Cleaver-Brooks representative for details.

Consult the following Cleaver-Brooks manuals for supplementary operating and maintenance information
regarding specific system options:

Level Master - 750-281

CB-PT Protocol Translator, CB-PTWS Protocol Translator with web server - 750-325

CB120E Burner Control - 750-264

CB780E Burner Control - 750-234

Variable Speed Drives - 750-198

O2 Trim - 750-224

Part No. 750-366 1-3

Section 1 — General Hawk 1000

1.3 Hawk 1000 System Features

• Burner Control controls burner start and shutdown sequencing and flame and interlock monitoring

• Compatible with CB780E and CB120E Burner Controls and Flame Scanners

• Boiler Control monitors and displays connected boiler parameters (operating pressure or temperature, stack
temperature, shell water temperature, O2% etc.)

• 4" color touch/keypad Human Machine Interface (HMI)

• Optimized boiler firing rate control

• Alarm/Fault Indication and History -- first out annunciation with time stamp and displayed in order of fault
occurrence

• Dual set point capability

• Thermal shock protection (includes warm-up routine, low fire hold & hot stand-by operation)

• Available input for any ONE of the following: remote modulation, remote set point, or Level Master water level
interface

• Available input for any ONE of the following: water temp (Steam)

• Return Temp or Outdoor reset (hot water boilers)

• Remote Modulation by communications (EtherNet)

• Remote Set Point by communications (EtherNet)

• Boiler efficiency calculation

• Assured Low Fire Cut Off

• External Interlock with auxiliary devices (fresh air damper/louvers, circulating pumps, etc.)

• High stack temperature alarm and shutdown

• Built-in two-boiler lead/lag capability (local set point only)

• EtherNet communications

• Three firing modes: Single-point, parallel, or LOW-HIGH-LOW

• Revert to Pilot control function (requires CB120E burner control)

• Supports control of a flue gas recirculation (FGR) damper

• Supports the control of a 2nd gaseous fuel actuator (Both Gaseous Fuels)

• OPC server software for building/plant automation system interface

• Remote monitoring software

• O2 monitoring and O2 trim (Option)

• Variable Speed Drive on combustion air fan (with bypass) (Option)

• Combustion Air Temperature Monitoring (Option)

1-4 Part No. 750-366

Hawk 1000 Section 1 — General

1.4 Safety Provisions and Diagnostics

1.4.1 Burner Management

• Utilizes CB780E or CB120E Burner Control

• Communicates with the PLC via Modbus

• Burner Control Status, Faults and Diagnostics displayed on HMI or panel mounted burner control

• Flame condition monitoring using either IR or UV Flame Scanner

Figure 1-3. CB 780E

1.4.2 Boiler Controls

• Operating and Modulating Controls

• Monitors Low Water Cut-Off

• Monitors Burner Control alarm terminal

• Non-Recycle Limit Relay de-energizes on PLC system errors or faults

• Transmitter input signal out of range alarms

• Actuator Modbus communication fault diagnostics

• Password protected system configuration and system set up screens

• Alarm Management incorporated into door-mounted HMI

• Password protection of Programmable Controller Logic

• Optional Variable Frequency Drive (VFD) fault shutdown

Figure 1-3. Burner Control Screen

Figure 1-4. Hawk 1000 Main Menu

Part No. 750-366 1-5

Section 1 — General Hawk 1000

1.5 Inputs and

Outputs

with O2, VSD or Comb Air Temp)

1

1

CB120E only)

Fire Oil Valve 2

1

1769 IA16 Digital Input 1769 OW8I Isolated Digital Output 1769 IF4 Analog Input (Optional

SM2

Dig IN Dig OUT Ana IN Ana Out

SP

I2/2 1

I2/3 1

Processor 1769-L24ER-QBFC1B - Slot 0 1769

Embedded I/O - Slot 1-3 Slot 4 Slot 5 Slot 6 Slot 7

High Limit Control I1/0 1 I5/0 Blower Terminal 1 O6/0 Recycle Limit (RLR) 1 I7/0 VSD Feedback 1

ALWCO I1/1 1 I5/1 Purge 1 O6/1 Start Ext. Device (FAD) 1 I7/1 O2 Signal 1

Low Fuel 1 Pressure/Low Oil Temp I1/2 1 I5/2 O2 Analyzer Status (Yokogawa) 1 O6/2 Non-Recycle Limit (NRLR) 1 I7/2 Comb Air Temp 1

High Fuel 1 Pressure/High Oil Temp I1/3 1 I5/3 VSD Status 1 O6/3 Prove Low Fire 1 I7/3 Reserved * 1

Low Fuel 2 Pressure I1/4 1 I5/4 Force to Low Fire 1 O6/4 Revert To Pilot (Fireye

High Fuel 2 Pressure I1/5 1 I5/5 Ready To Start/ Limits Closed 1 O6/5 Prove High Fire / Open High

Oil Drawer Switch I1/6 1 I5/6 Ext. Device Start Interlock (FAD) 1 O6/6 Alarm Bell 1

Atomizing Air Pressure I1/7 1 I5/7 ALFCO 1 O6/7 Open High Fire Oil Valve 1 1

Combustion Air Pressure I1/8 1 I5/8 Pilot Terminal 1

High Water (ST) or Flow Sw. (HW) I1/9 1 I5/9 Main Fuel Terminal 1

VSD Bypass I1/10 1 I5/10 Fuel 1 Selected 1

High Combustion Air I1/11 1 I5/11 Fuel 2 Selected 1

Spare I1/12 1 I5/12 Burner Control Alarm Terminal 1

Auxiliary Alarm 1 I1/13 1 I5/13 Low Water Alarm 1

Auxiliary Alarm 2 I1/14 1 I5/14 Lead Boiler / Sel Rem Mod / Sel

Auxiliary Alarm 3 I1/15 1 I5/15 Burner Switch 1

Reserved * O1/0 1

Ready for Lead/Lag O1/1 1

Spare(s) O1/2-O1/15 14

Steam Pres (ST) / Supply Temp (HW) I2/0 1

Stack Temp I2/1 1

Water Temp (ST) / Outdoor Temp

(HW) / Return Temp (HW)

Water Level (ST) / Rem Mod / Rem

Set Point

VSDControl O2/0 1

Firing Rate O2/1 1

High Speed Counter (NOT USED) Slot 3

Total 16 16 4 2 16 8 4

* Reserved for future add

1-6 Part No. 750-366

Section 2

System Components

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Human-Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Steam Systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Hot Water systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

www.cleaverbrooks.com

Section 2 — System Components Hawk 1000

2.1 Overview

The principal components of the HAWK 1000 Boiler Control System are the Programmable Logic Controller
(PLC), Touch Screen Human Machine Interface (HMI), and the Flame Safety Control. The system also includes
24VDC power supplies and various relays and circuit breakers.

1

1a

686

1. Base Unit
1a. L24ER Programmable Logic Controller (PLC)
1b. Embedded I/O

2. SM2 Modbus Communications Module

3. Digital Inputs

4. Digital Outputs

5. Analog Inputs (optional)

6. Burner Control

7. Power supplies

8. Circuit breakers, relays, fuses,

9. ALWCO control

1b

Figure 2-1. Hawk 1000 Panel

etc.

2

7

4

3

5

9

The

HAWK
watertube boilers, yet allows easy configuration for specific boiler applications. The Boiler Controller
logic is password secured, ensuring tamper- proof controller operation. The Touch Screen HMI provides
friendly access to firing rate control functions, boiler diagnostics and alarm histor y, as well as
operating
Safety Control.

1000

parameters.

Boiler Controller is factory pre-programmed to work with most Cleaver-Brooks firetube

Burner

management

progra

conn

is handled by the proven CB780E or optional CB120E

Flame

2.2 Base Unit

The Base Unit consists of the Processor (CPU) which holds the program logic and configuration for the boiler
controller and embedded I/O modules which consist of discrete inputs, discrete outputs, and analog inputs.
The program logic is password-secured at the factory.

The SM2 module handles the Modbus communications between the PLC and other devices.

2-2 Part No. 750-366

and

m

user

ected

-

Hawk 1000 Section 2 — System Components

The Module Power Supply powers the Base Unit and the I/O modules. The remainder of the PLC rack is for
the discrete input and output modules, and for analog input module (optional).

I/O modules are used to send and receive control and communication signals to/from other parts of the system.

Slot Module

0

1

2

3

4

5

6

7

A Right End Cap Terminator is required to complete the modular communication bus. It attaches to the right
side of the last module in the rack.

An optional analog input module can be added to the PLC to provide additional functionality.

DISCRETE and ANALOG Signal Types
Discrete inputs/outputs are used for signals taking on only one of two

possible states (on/off, open/close, etc.). The input state is represented
by a bit (0 or 1) in the control logic. Example:

Boiler Ready (yes/no)
Analog signals can assume almost infinite values within the fixed

analog input/ output current range of 4-20 mA. The Hawk 1000 PLC
converts this current value to a range in engineering units. Example:

Steam Pressure (0-150 PSI)

1769-L24ER-QBFC1B Processor

Embedded Discrete Inputs/Outputs

Embedded Analog Inputs/Outputs

Embedded High Speed Counter

SM2 Modbus Module

Digital Input Module

Relay Output Module

Analog Input Module (4 ch. - optional)

BASE
UNIT

NOTE: The PLC program expects each device to be in a specific slot location. The HAWK 1000 controls
will not function unless all devices are properly installed and configured.

2.3 Human-Machine Interface (HMI)

The HMI displays numerous boiler parameters at a glance and provides easy menu navigation for configuring
system parameters, setting of combustion, monitoring the boiler processes, and managing and annunciating
system alarms.

The HMI communicates with the PLC via Ethernet and is

Part No. 750-366 2-3

powered

by a 24

VDC

din-rail mounted power

supply.

Section 2 — System Components Hawk 1000

Figure 2-2. Firing Rate screen

2.4 Communications

2.4.1 Modbus

Modbus is an open serial protocol used by the
commands,
communications

HAWK 1000 devices that communicate using Modbus include the burner flame safety control and the fuel, air,
and FGR actuators. The Modbus communication network allows burner control system status and fault
information to be transmitted to the PLC and displayed on the HMI screen, and in addition is used for actuator
control, feedback, and fault information.

position data, and diagnostic data between the

are managed by the SM2 module located to the right of the base unit in slot

Figure 2-3. SM2 Modbus Module

HAWK

1000 system

PLC

and attached

for sending and receiving control

devices.

Modbus

4.

2-4 Part No. 750-366

Hawk 1000 Section 2 — System Components

2.4.2 Ethernet

The

HAWK

1000

uses Ethernet for several communication functions:

• Communication between the PLC and HMI. The Ethernet cable connecting the PLC and HMI can be either
a straight through or a crossover type.

• Connection of the boiler control system to an existing infrastructure, i.e. plant Local Area Network (LAN)

• Integration with a Building/Plant Automation System (BAS)

• Remote monitoring of boiler control system via the customer's Wide Area Network (WAN) or via the Internet

• Connection of a laptop for diagnostics

Ethernet/IP is also used for control functions. Individual boiler controllers may be networked to facilitate lead/lag
control, with a single BAS interface for multiple boiler systems.

2.4.3 USB

USB communications are used to connect a laptop computer for diagnostic purposes.

PORT 1

PORT 2

Ethernet ports (bottom of Base Unit)

Figure 2-4. L24ER Communication Ports

USB
PORT

00:00:BC:2E:69:F6

L24ER

QBFC1B

+24VDC COM FG

+24VDC C OM FG

01234567

01234567

8 9 10 11 12 13 14 15

SINK\

24VDC

SOURCE

SINK\

8 9 10 11 12 13 14 15

24VDC

SOURCE

01234567

24VDC

01234567

SOURCE

24VDC

SOURCE

8910

8910

DC IN

00

08

01

09

02

10

03

11

04

12

05

13

06

14

07

15

COM

COM

0

1

NC

NC

+V

+V

00

08

01

09

02

10

03

11

04

12

05

13

06

14

07

15

COM

COM

0

1

DC OUT

11 12 13 14 15

11 12 13 14 15

DC

DC

INPUT

DC

DC

OUTPUT

A0+

B0+

Z0+

A1+

B1+

Z1+

+V

OUT

OUT

COM COM

CJC

CJC

OUT

OUT

A0 B0 Z0

A0 B0 Z0

INOUT

A1 B1 Z1

INOUT

A1 B1 Z1

INPUT

COUNTER

0 2 FUSE

HIGH SPEED

COUNTER

0 2 FUSE

HIGH SPEED

13OK

OUTPUT

13OK

HSC

A0-

B0-

Z0-

A1-

B1-

Z1-

+V

OUT

2

0

0UT

1

3

V

V

in

in

0+

2+

I

I

in

in

0+

2+

V/I

V/I

in

in

0-

2-

V

in

+

3+

I
in

­3+

V

V/I

in

in

1+

3­V/I

I

in

in

1-

1+
V

V

OUT

0+

1+

I

I

in

0+

1+

COMCOM

ANALOG

Part No. 750-366 2-5

Section 2 — System Components Hawk 1000

2.5 Sensor Inputs

The following table shows the sensors available as standard and as options for steam systems (ST) and for
hot water (HW) systems:

Sensor System Standard Optional

Steam Pressure ST Yes
Stack Temperature ST & HW Yes
Water Temperature ST Yes
Water Level ST Yes
Supply Temperature HW Yes
Outdoor Temperature HW Yes
Return Temperature HW Yes

All systems use RTDs with a transmitter to produce 4-20mA output for

temperature detection.

2.5.1 Steam Systems:

Steam Pressure is the primary sensor input to the HAWK 1000 Controller in a Steam System. It transmits a

4-20mA process variable signal to the Controller that is used to control Firing Rate and the Operating Limit
Control.

Stack Flue Gas Temperature is used for High Stack Temperature alarms and shutdown. It is also used in the
boiler efficiency calculation.

Water Temperature (mandatory on steam boilers) measures boiler-shell water temperature and is use d for
thermal shock protection and hot standby control on steam boilers. The standard location for the thermowell is
a 1/2” NPT coupling at the right-hand side center-line of the boiler shell. If this location is not available, an
unused feedwater connection may be used.

Water Level sensor is OPTIONAL on steam boilers, but must be a CB Level Master.

2.5.2 Hot Water systems:

Supply Temperature is the primary sensor input to the HAWK 1000 Controller in a Hot Water system. It

transmits a 4-20mA process variable signal to the Controller that is used to control Firing Rate and the
Operating Limit Control.

Outdoor Temperature is used in Hot Water Systems with the Outdoor Temperature Reset Option.

Return Temperature is used in Hot Water Systems with the Return Temperature option and is monitor only.

NOTE: The Outdoor Temperature and Return Temperature sensors use the same input. One or the other can

be used with the Hawk 1000, but not both.

2-6 Part No. 750-366

Section 3

Hardware Checkout

Control Panel Component Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

DIN Rail Latch and Expansion I/O Module Locking Levers . . . . . . 3-2

Panel and Field Wiring Terminations . . . . . . . . . . . . . . . . . . . . . 3-3

SM2 Module DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Burner Control Modbus Address and Baud Rate - CB780E . . . . . 3-4

Burner Control Modbus Address and Baud Rate - CB120E . . . . . 3-6

PLC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Modbus Actuator Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Setting The Modbus Node Address . . . . . . . . . . . . . . . . . . . . . . 3-9

Power/ Communications LED . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Moving The Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

www.cleaverbrooks.com

Section 3 — Hardware Checkout Hawk 1000

Important

!

The base unit and expansion modules do not support removal and insertion under power. While the PLC
system is under power, any break in the connection between the power supply and the base unit (i.e.
removing the power supply, base unit, or an expansion module) will clear processor memory including the
user program. Ensure that the electrical power is OFF before removing or inserting any PLC device.

3.1 Control Panel Component Checks

This section will cover the initial system checkout to be done prior to configuring and commissioning the
system through the HMI menu system.

It is necessary to confirm that all of the integral components and interconnecting wiring are in place and
secure. Vibration and jarring from transport or installation may have loosened components or wiring terminals.
It is good practice to check all system components for integrity and tightness prior to initial power-up of the
system. Any external interlock and remote signal wiring should also be connected to the boiler controller.

3.1.1 DIN Rail Latch and Expansion I/O Module Locking Levers

Before powering up the control system for the first time, check that all the DIN rail latches and expansion
module locking levers are in place (see Figure 3-1 and Figure 3-2).

Figure 3-1. DIN rail latches

Figure 3-2. Expansion I/O Module locking levers

The module locking levers should all be securely seated to the left.

3-2 Part No. 750-366

Hawk 1000 Section 3 — Hardware Checkout

3.1.2 Panel and Field Wiring Terminations

Check that all factory wiring connections are tight and that field wiring terminations are completed and secure.

Figure 3-3. Check all wiring and connections

3.1.3 SM2 Module DIP Switch

Verify that the SM2 Module DIP switch setting is as shown below (the top switch is to the left, the bottom
switch is to the right).

DIP switch
settings: Top L,
Bottom R

Figure 3-4. SM2 module DIP switch setting

Part No. 750-366 3-3

Section 3 — Hardware Checkout Hawk 1000

3.1.4 Burner Control Modbus Address and Baud Rate - CB780E

The CB780E Modbus node address should be set to 05 and the baud rate to 9600. Settings are made using
the 780E keypad display.

Press the left three buttons of the keypad display module for one second, then release.

DISPLAY Setup will appear.

Press the two ENTER buttons at the same time.

Press down arrow until MB ADDRESS is displayed.

Press ENTER buttons at the same time.

Press down arrow twice.

Set Modbus address to 05 by using up and down arrow keys.

Press ENTER buttons at the same time.

3-4 Part No. 750-366

Hawk 1000 Section 3 — Hardware Checkout

Press down arrow key to save changes.

Press down arrow key until MB BAUD is displayed.

Press ENTER buttons at the same time.

Press down arrow to select.

Using up or down arrow key select 9600.

Press ENTER keys at the same time.

Part No. 750-366 3-5

Section 3 — Hardware Checkout Hawk 1000

Press down arrow key to save changes.

Press ENTER buttons at the same time.

Press upper arrow key to exit.

3.1.5 Burner Control Modbus Address and Baud Rate - CB120E

The CB120E has built-in Modbus capability; for proper communications the ModBus baud rate and node
address need to be correctly set. To check the settings, the CB120E must be powered.

Press the <BACK> or <NEXT> key on the CB120E display until the screen displays PROGRAM SETUP>.

3-6 Part No. 750-366

Hawk 1000 Section 3 — Hardware Checkout

Press the <MODE> then the <NEXT> key until the screen displays BAUD RATE.

Press <MDFY> and use the <BACK> or <NEXT> key to change to 4800. Press <MDFY> to save.

Press the <NEXT> key until UNIT ADDRESS # is displayed. To change the unit address, use the <BACK>
or <NEXT> key to change to 5. Press <MDFY> to save.

Press <MODE> to exit the menu.

3.1.6

Verify

The boiler will not operate if the switch is in the PROG

The boiler will immediately stop if the switch is moved to the

The switch must be in the PROG position and the Burner switch set to OFF before the PLC program
be copied to a blank SD card in “

The switch can be in either PROG or RUN position when copying a PLC program from a SD
a

3.2 Modbus

PLC

Switch

that the PLC switch is in the RUN

Logix

folder. No other files should be present on the SD

Actuator

Checks

position

Logix

folder” format.

.

position

.

PROG position.

can

card

containing

card.

3.2.1 Mounting

Fasten the actuator using bolts through the mounting bracket, threaded into the face of the actuator. Be
sure

that the mounting

surface

rests flat against the mounting bracket and is

secure.

The actuator output drive shaft should be connected to the valve shaft with a suitable coupling. The
coup

ling

may be connected with set screws and pinned in position or secured with a key.

It is recommended that the actuator drive shaft remain decoupled from
shaft (or damper level) until the actuator Modbus address is properly set, the wiring
is proven, and the direction of rotation to open the valve/ damper is determined.

the valve

3.2.2 Electrical Connections

(from

The actuators are intended to have one cable connection on the incoming side,

the previous actuator
or the Hawk panel) and one cable connection on the outgoing side, to the next actuator. The cable
connectors
align the
the cable.
movement of the

In some installations, codes or other requirements may call for the actuators to be hard wired. See Figure

Part No. 750-366 3-7

and mounting plugs are keyed to ensure that the pins all line up correctly. To connect the cable,

pins

and the key and push into place. Turn the threaded collar clockwise to tighten and secure

Secure

the cables such that the cables are not pinched and do not in

actuated

devi

ces.

terfere

with the mechanical

3-7.

Section 3 — Hardware Checkout Hawk 1000

Figure 3-5. SM2 wiring to actuators

MODBUS ACTUATORS PLUG WIRED

FUEL 1
ACT. 1

Figure 3-6. Actuator daisy chain w/ plug connections

FUEL 2
ACT. 1

3-8 Part No. 750-366

Hawk 1000 Section 3 — Hardware Checkout

MODBUS ACTUATORS HARD WIRED

FUEL 1
ACT. 1

FUEL 2
ACT. 1

Figure 3-7. Actuator daisy chain hard wired

3.2.3 Setting The Modbus Node Address

The actuators are required to have unique Modbus node addresses. The node address is set using a rotary
style switch located on the actuator front plate. Turn to the desired address using a small, flat bladed
screwdriver.

Part No. 750-366 3-9

Section 3 — Hardware Checkout Hawk 1000

Rotary switch - set
node address

Power/Command LED

Figure 3-8. Modbus Actuator

Once the node address has been set, the actuator may be powered up.

Power must be cycled to the actuator before a new node address setting will be accepted by the actuator.

Actuator Node Address Table:

Actuator Address
Air Actuator 1
Fuel 1 Actuator 2
2nd Fuel 1 Actuator 3
Fuel 2 Actuator 5
2nd Fuel 2 Actuator 6
FGR Actuator 7

3.2.4 Power/ Communications LED

Each actuator has a green Power/ Communications LED. The LED can assume one of three states:

OFF - check that 24 VDC power is present. The LED is also OFF when pressing either the CCW or CW red
pushbutton.

ON Solid - power present but no commands received from PLC. ON Solid is the normal state for an actuator
not required by the PLC at the time - such as the Fuel 2 Actuator when the Fuel Selector is in the Fuel 1
position.

Rapid Flickering - actuator is responding to PLC commands and sending position data.

3-10 Part No. 750-366

Hawk 1000 Section 3 — Hardware Checkout

3.2.5 Moving The Actuator

The actuator can be moved clockwise or counterclockwise by pressing either one of two red buttons

located
on the actuator (Figure 3-9). One red button moves the actuator shaft clockwise, and the other moves
the

actuator shaft counter-clockwise. The servo will automatically stop when it reaches the end of its

travel.

Moving of actuators manually should only be done when the main fuel valve is closed. Moving the actuators
manually while the main fuel valve is open will generate a fault.

Releasing the manual pushbutton will allow the PLC to automatically command the actuators to position;
therefore the buttons should not be used during commissioning, but only as a troubleshooting tool.

There are open/ close pushbuttons on the actuator calibration screen
should be used when calibrating the actuators.

Clockwise or counter-clockwise actuator shaft
Figure

3-9.

rotation

Counterclockwise (CCW)

is deduced

from

on the

the viewing perspective shown in

HMI. These pushbuttons

Clockwise (CW)

Figure 3-9. Actuator manual pushbuttons

Part No. 750-366 3-11

Section 3 — Hardware Checkout Hawk 1000

3-12 Part No. 750-366

Section 4

System Configuration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Boiler Type and Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Fuel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

Remote Modulation/Remote Set Point . . . . . . . . . . . . . . . . . . . . 4-15

Actuator Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

Variable Frequency Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Configuration Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23

www.cleaverbrooks.com

Section 4 — System Configuration Hawk 1000

4.1 Introduction

The Hawk 1000 is equipped with a 4" color touch screen Human Machine Interface (HMI). The HMI along
with the Burner Control display are the points of interface for the operator to monitor and control the boiler,
and for the technician to configure and set up the system.

This section describes the HMI screens and their functions.

For information on the Burner Control (Flame Safeguard), refer to one of the following CB publications:

CB120E Burner Control 750-264

CB780E Burner Control 750-234

Figure 4-1. Firing Rate Screen

A gray button on the HMI indicates that a password is required before user input is allowed. The Hawk 1000
employs three levels of security: Operator, Service, and Factory. Pressing a gray pushbutton will display the
login entry window.

4.2 Main Menu

The Main Menu (Figure 4-2) is the first screen to appear when power is applied to the system. A header
section at the top of the screen shows the current date and time, the user login status, a logout button and
an alarm bell if an alarm is present. The rest of the screen consists of screen navigation buttons.

When the system is powered on for the first time (Figure 4-3), the <System Config>* button will indicate “System
Config Required”. The screen will indicate “Commissioning Not Done” until initial configuration and commissioning have
been completed. Note also that some screen buttons will not yet be available.

*In this manual, screen buttons

on

the HMI are identified by the

button

description with arrows on

either

side (e. g. <Main>

).

4-2 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

Figure 4-2. Main Menu (all possible screens)

Figure 4-3. Main Menu (initial startup)

4.3 Boiler Overview

The Boiler Overview display (Figure 4-4) serves as the main point of interface for the operator. The primary
purpose of the display is to monitor the current status of the boiler.

Part No. 750-366 4-3

Section 4 — System Configuration Hawk 1000

Firetube

Model 4/5

Figure 4-4. Boiler Overview

4.4 System Configuration

The first step in commissioning the boiler is to
configure the control
Screen press <

System

system

options. On the Main

Config

>.

Flextube

A warning message is displayed:

Press <

System

Config

> again; a final warning

screen will appear:

Figure 4-5. Warning 1

4-4 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

Figure 4-6. Warning 2

Press <Next> to continue. The following items are configurable when in system configuration:

• Boiler Media Steam or Hot Water

• Boiler Type - Firetube, Flextube or M4/M5 boiler

• Safety Valve Setpoint

• NOx Level (PPM)

• Number of Fuels

• Fuel 1 Fuel Type

• Fuel 1 Control Type (Parallel or Single Point)

• Fuel 1 Turndown

• Fuel 2 Fuel Type

• Fuel 2 Control Type (Parallel, Single Point, or Low High)

• Fuel 2 Turndown

• Flame Safeguard Selection

• Revert to Pilot (CB120E Only)

• Revert to Pilot Signal Select (CB120E Only)

• Analog Input I:2.2

• Analog Input I:2.3

• Remote Modulation/Setpoint Signal Selection

• Dual Setpoint Selection

• Actuator Selection

• VFD Option Selection (requires additional analog input module Slot 7)

• VFD Bypass Option Selection

• O2 Analyzer (when this option is selected, type of analyzer must be specified - requires additional analog input
module Slot 7)

• O2 Trim

• Low O2 Shutdown Option

• Hot Standby Option Selection

• Combustion Air Temp Option Selection (requires additional analog input module Slot 7)

• Level Master Option selection (Steam Boiler)

• Return Water Temperature (hot water only)

• Outdoor Temp Reset Selection (hot water only)

• Selectable overview screen graphic - Firetube, Flextube, or M4/M5 boiler

Part No. 750-366 4-5

Section 4 — System Configuration Hawk 1000

Note that if a configuration setting is marked with an asterisk and the setting is changed the Combustion
Curves will be erased.

Caution

!

If System Configuration is entered with the boiler running, a safety
shutdown will occur. Repeated shutdowns or nuisance shutdowns
can cause premature equipment failure.

Caution

!

The following screens should only be accessed by qualified
personnel. Selections should never be made while the boiler is in
operation.

Note: The boiler will not start while you are in the “System Config” screen.

Note: The firing rate will be put into manual mode upon entering the “System Config” screen.

4.4.1 Boiler Media and Type

The first step in the configuration procedure is to select the boiler media and type.

Figure 4-7. Select boiler media & type

Any time a gray button appears, a user I.D. and password are required for user input.

Pressing <Boiler Media> or <Boiler Type> will bring up the following screen:

4-6 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

Pressing <User> or <Password> will bring up an alphanumeric keypad. Use this (or the HMI hardware
keypad) to enter your user name and password. A USB keyboard may also be used.

Type the password (user name) followed by the Enter key.

When a valid user name and password are entered, the following screen will appear:

Part No. 750-366 4-7

Section 4 — System Configuration Hawk 1000

Figure 4-8. System configuration

In this example, “Firetube” is selected as the boiler type. After selecting the boiler media (steam or hot water)
additional screen buttons will become available. Selecting “Steam” will bring up buttons for steam transmitter
span, safety valve setpoint, and NOx level. To change the default values, press the desired button and a keypad
will appear allowing user input.

Selecting boiler type and media will also bring up the <Next> button, allowing the user to advance to the
next configuration screen.

The user must be logged in at the appropriate password level to change configuration data. If the user tries to
change configuration data without having proper access rights, a pop-up window will appear and a password
will be requested.

Figure 4-9. Media selected

4-8 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

If a valid user name and password are entered, the operator will be allowed to change data. The current user
login status can be seen in the top right corner of each screen.

The color of the pushbutton will also indicate if the user has proper access rights.

Pressing the button of the value that needs modifying will pop-up a numeric keypad, allowing the operator to
enter the new value. Notice that there is a range of valid entries at the top of the numeric keypad. An out-of­range entry will show up in red and require re-entering an acceptable value.

Enter the desired value and press the Enter key. If the entry is valid, the value will be accepted and the keypad
will disappear. Note that all entries can be made by touching the HMI screen or by using the HMI keypad.

Numerical values
may be entered
from here or from
the popup numeric
pad on the screen

Popup keypad Invalid entry

Boiler Media

Select Steam or Hot Water depending on the type of system.

Boiler Type

The Boiler Type will display the proper Boiler graphic on the Boiler overview screen

.

The three choices for

Boiler Type are: Firetube, Flextube and M4/M5

Boiler Type is also used to set limits on the maximum entry allowed for Safety Valve Setpoint (steam) or Max
Rated Temperature (hot water).

Safety Valve Setpoint Max
Firetube 400 psi
Flextube 250 psi
M4/M5 600 psi

Maximum Rated Temperature (Hot Water)

All Types = Between 200-400 Deg F

Part No. 750-366 4-9

Section 4 — System Configuration Hawk 1000

Safety Valve Setpoint (steam)

On a steam boiler, the proper safety
safety

valve(s) on the boiler.

Warning

!

The safety valve setting is critical to the proper operation of
boiler. An incorrect setting could lead to unsafe

A

hot water boiler is configured similarly. The max rated temperature

number should not exceed

the
is 250º F. Contact your local Cleaver-Brooks representative if you do not know the maximum
rating of your

boiler.

valve

setting should correspond to the pressure setting of the steam

maximum design

operation

.

temperature

the

of the boiler should be entered. This

of the boiler. Default for hot

water

temperature

boilers

Steam Transmitter Span The span settings for the steam transmitter is adjustable. The Steam Transmitter
Span value cannot be set lower than the Safety Valve Setpoint and cannot be set higher than 1000. Initially
the Steam Transmitter Span is populated with a default value:

Safety Valve Setpoint Steam Transmitter Span

15.0 psi or less 15.0

15.1 to 150.0 150.0

150.1 to 300.0 300.0

300.1 to 500.0 500.0

500.1 to 600.0 600.0

In hot water systems the supply temperature transmitter is not scalable. The transmitters used must be rated
to accommodate the required range:

If the Max Rated Temperature > 250 Deg F the Supply Temp Transmitter is set to 50-300 Deg F.

If the Max Rated Temperature = 250.1 Deg F or greater the Supply Temp Transmitter is set to 50-500 Deg F.

NOx Level (PPM)

Enter the NOx Level for this specific job

.

NOx Level can range from 5-150 PPM and is initialized with a value of 60.0 PPM.

Note: On Steam Boilers If NOx Level is less than 60.0 PPM Remote Setpoint and Dual Setpoint Options
are Not Available

.

When all configurable items on this screen have valid entries, the <Next> button will appear, allowing System
Configuration to continue. The next screen is fuel configuration, where number and type of fuels, turndown,
and combustion control method are selected.

4-10 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

4.4.2 Fuel Configuration

Figure 4-10. Fuel configuration

Number of Fuels

Enter the Number of Fuels for this application

.

Acceptable values are either 1 or 2. High/Low control method MUST be fuel 2.

Fuel 1/Fuel 2 Type

Select the Fuel type for each fuel for this specific job

When pressing the Fuel Type push button a selector is displayed

The up/down arrows can be used to select the correct fuel. Press the enter key to accept the selection.

Fuel 1/Fuel 2 Turndown

Enter the Turndown for each fuel for this specific application.

The turndown entr y affects the boiler efficiency calculations - it has
turndown. Turndown ratio is established

Part No. 750-366 4-11

during burner commissioning by a qualified burner technician

no

impact on the burner's actual

.

Section 4 — System Configuration Hawk 1000

Fuel 1/Fuel 2 Control Method

Select the type of control method for each fuel for this specific job.

Acceptable values for fuel 1 are Parallel Positioning or Single Point positioning.

Acceptable values for fuel 2 are Parallel Positioning, Single Point positioning or Low/High.

Note - Single Point positioning cannot be selected in conjunction with parallel positioning.

When fuel configuration is complete, press <Next> to go to Flame Safeguard configuration.

4.4.3 Flame Safeguard

Figure 4-11. FSG screen

Flame Safeguard

Select the type of Flame Safeguard used for the specific job.

The CB780E and CB120E are the two selections available on the Hawk 1000

If CB120E is selected the Revert to Pilot Option is available (not available on the CB780E).

Revert to Pilot

The Revert to Pilot selection is made by pressing the <Revert to Pilot> push button until “Yes” is displayed
on the pushbutton.

If Revert to Pilot is selected there are two ways to initiate the Revert to Pilot sequence - either by Process
Variable (Steam Pressure/Supply Temperature) or by Digital Input.

If Process Variable is selected the setpoint for Revert to Pilot must be entered from the Setpoint Screen - see
Section 5 E - Setpoints for more details.

If Digital Input is selected, when discrete input I:5.7 ALFCO is turned off, Revert to Pilot will be initiated.

4-12 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

Caution

!

Revert to Pilot modes are to be determined in the field

after

careful

analysis of the load conditions that necessitate the use of these mode

r

of ope

Care should be taken to avoid
boiler equipment.

ation.

unnecessary

recycling and damage to the

4.4.4 Analog Inputs

Figure 4-12. Analog Inputs (steam)

Analog Input I:2.2

For Steam systems it is mandatory that Analog Input I:2.2 is Water Temperature

For Hot Water systems Analog Input I:2.2 can be selected as None, Outdoor Temperature, or Return
Temperature.

Part No. 750-366 4-13

Section 4 — System Configuration Hawk 1000

Figure 4-13. Analog Inputs (hot water)

Analog Input I:2.3

For Steam systems Analog Input I:2.3 can be selected as None, Water Level, Remote Modulation, or Remote
Set Point. If Water Level is selected it is mandatory that the Level Master is the sensor used to measure the
water level. Remote Set Point is not available on Low Emission boilers <60ppm.

750-281

Level

Master

For Hot Water systems Analog Input I:2.3 can be selected as None, Remote Modulation, or Remote Setpoint

If Analog Input I:2.3 is used for Remote Modulation or Remote Set Point then neither Remote Modulation by
communications or Remote Setpoint by communications are available.

4-14 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

4.4.5 Remote Modulation/Remote Set Point

Signals for Remote Modulation or Remote Setpoint can be provided by either an analog input signal or written
directly into the PLC by communications (Ethernet).

Figure 4-14. Remote Mod/Setpoint by Communications

Remote Modulation by Analog Input

This configures the Boiler Controller
rate of the

boiler.

receive a remote 4-20mA signal on input I:2.3 to control the

firing

to

The signal is scaled from 0-100%, (4ma = Low Fire and 20ma = High Fire).

Remote Modulation by Analog Input Signal Selection

The user can select between HMI or digital input to enable Remote Modulation.

Select <Digital In> if another control system will enable Remote Modulation by isolated contact input signal
(120 VAC) on digital input I:5.14. When that input is de-energized, the Boiler Controller will revert back to
local firing rate control. If Remote Modulation operation will be enabled manually, select <HMI Input>.
Remote Modulation can then be enabled, by selecting the <Remote> button on the Firing Rate Screen.

If the PLC detects a bad analog signal, an alarm “Remote Modulation Signal Failure” is activated and the Firing
Rate revert to the LOCAL setting on the HMI.

Part No. 750-366 4-15

Section 4 — System Configuration Hawk 1000

Figure 4-15. Remote Modulation signal select

Remote Modulation by Communications

This configures the Boiler Controller

to

receive a Remote Modulation signal directly by Communications
(Ethernet). Modulation units range from 0-100%. Communication integrity is determined by a Communication
Heartbeat signal between the Control System and the Building Management System. If a Communications
failure is detected, an alarm message “Remote Communications Failed” is displayed on the HMI and
Modulation reverts back to the LOCAL setting on the HMI

Remote Set Point by Analog Input

This configures the Boiler Controller

receive a remote 4-20mA signal on input I:2.3 to vary the

set

point

to

of the boiler.

Note: Remote Setpoint is not allowed for low emission steam boilers

.

With Remote Setpoint selected, the analog signal can be scaled to the engineering units on the “Alarm and

the

Limits” Screen, by setting the Remote Setpoint Scaling values (zero and span) of

remote 4-20mA signal

Remote Set Point by Analog Input Signal Selection

The user can select between HMI or digital input to enable Remote Set Point.

Select <Digital In> if another control system will enable

VAC) on digital input I:5.14.

(120
local

setpoint control. If Remote Set point operation will be

Remote Setpoint can then be

When

that

enabled,

input is de-energized, the Boiler Controller will revert back to

by selecting the

R

emote

Set Point by isolated contact input signal

enabled

<Remote>

manually, select <HMI

button on the Firing Rate

Input>.

Screen

.

If the PLC detects a bad analog signal, an alarm “Remote Setpoint Signal Failure” is activated and the Set
point revert to the LOCAL setting on the HMI.

Remote Set Point by Communications

This configures the Boiler Controller

to

receive a Remote Set Point signal directly by Communications
(Ethernet). Setpoint is written in engineering units. Communication integrity is determined by a
Communication Heartbeat signal between the Control System and the Building Management System. If a

4-16 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

Communications failure is detected, an alarm message “Remote Communications Failed” is displayed on the
HMI and Setpoint reverts back to the LOCAL setting on the HMI

Warning

!

Remote Set Point control should not be used on certain Low
Emission boiler systems. Low Emission boilers can be
changing operating set points. Contact your Cleaver-Brooks
representative
your boiler. Failure to follow these precautions may result in
damage to equipment, serious personal

Dual Set Point

Dual Set Point control - traditionally referred to as night setback - allows the Boiler Controller to easily switch
from the primary set point (Set Point 1) to the setback set point (Set Point 2). Set Point 1 is the primary set
point for the Controller and is the only set point available if the Dual Set Point option is disallowed (see below).
Setback can be initiated manually (through the HMI on the Firing Rate screen) or remotely (by energizing an
isolated contact input signal (120 VAC) on digital input I:5.14. Press the button to the right of “Dual Set Point
Selection By” to toggle between <HMI Input> and <Digital In>.

to determine if Remote Set Point

injury,

control

or

sensitive

is

death.

allowed

to

on

The Dual Set Point option is not allowed when Remote Modulation, or Remote Set Point options are enabled.

Selecting <Yes> to Dual Setpoint enables dual Set Point control. This option is not allowed for low emission
steam boilers (<60 ppm).

Warning

!

Dual Set Point control should not be used on certain Low Emission
boiler systems. Low Emission boilers can be sensitive to changing
operating set points. Contact your Cleaver-Brooks representative to
determine if Dual Set Point control is allowed on your boiler. Failure
to follow these precautions may result in damage to equipment,
serious personal injury, or death.

4.4.6 Actuator Selection

FGR Actuator

The FGR actuator should be selected as “Yes” if it is present on this system. This actuator is only available for
parallel positioning control.

Fuel 1 Actuator 2

The Fuel 1 Actuator 2 should be selected as “Yes” if it is present on this system. This actuator is only available
for parallel positioning control.

Fuel 2 Actuator 2

Part No. 750-366 4-17

Section 4 — System Configuration Hawk 1000

The Fuel 2 Actuator 2 should be selected as “Yes” if it is present on this system. This actuator is only available
for parallel positioning control.

Figure 4-16. Actuator selection

4.4.7 Variable Frequency Drive

VFD Type

Select the appropriate VFD Type for this specific job.

The available options are None, PowerFlex, and Other Mfg.

Selecting <PowerFlex> assumes you are using either the PowerFlex 400, PowerFlex 70 Enhanced, or
PowerFlex 700 Vector drive.

All drives types use 4-20mA command and feedback.

VFD Bypass

VFD Bypass should be selected “Yes” if VFD Bypass is on this specific job.

An Air/Fuel curve must be configured for each fuel while in bypass mode.

VFD bypass allows the boiler system the ability to keep the combustion blower motor running even if the
Variable Frequency Drive is taken out of the loop for any reason.

4-18 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

Figure 4-17. VFD screen

Variable Frequency Drive for Combustion Air Fan Motor

Variable frequency drives (VFDs) offer many benefits to reduce energy costs and extend the life of mechanical
equipment.

The optional Variable Frequency Drive (VFD; see Figure 2-7) controls the speed of the combustion air fan
motor for the purposes of improving boiler efficiency and reducing electrical energy consumption.

4.4.8 Options

Oxygen Analyzer

The Oxygen (O2) Analyzer (See Figure 2-8) is available for monitoring stack flue gas oxygen concentration. The
O2 Analyzer transmits an analog signal to the controller. The O2 signal is used for Low O2 alarms, Low O2
Shutdown and in calculating boiler efficiency. O2 concentration is displayed on the Boiler Overview and Firing
Rate screens.

Figure 4-18. O2 Analyzer

Part No. 750-366 4-19

Section 4 — System Configuration Hawk 1000

O2 Trim

02 trim control is an integral part of the HAWK 1000 system. This feature affords additional control over fuel-to­air ratios in the event of adverse atmospheric conditions or fluctuating fuel heating values.

The HMI has an 02 trim screen that displays O2 Actual concentration and O2 Setpoints. The Screen allows for

viewing and calibrating the Cleaver Brooks O2 Sensor (CB) and also

allows for adjustment of PID tuning. The

Flue Gas O2 Control Screen can be accessed from the HMI Main screen.

Figure 4-19. Flue Gas O2 Control Screen

Low O2 Shutdown

Low 02 Shutdown is a feature that allow the boiler to be shutdown if O2 concentrations become too low.

Low O2 Shutdown can be enabled or disabled b y
screen)

between

<Yes> and <No>

.

toggling “O2 Shutdown” (on the System Configuration

If enabled the Low O2 Shutdown Setpoint and Low O2 shutdown time delay can be adjusted on the alarms
and limits screen.

Hot Standby

The Hot Standby function maintains a minimum water temperature to keep the boiler in a state of readiness
for a load demand. While operating, the boiler

remains at the minimum firing rate and cycles on-and-off

relative to the Hot Standby water temperature set point. This set point is configured on the Setpoints screen
(accessed from the Main Screen).

Hot Standby can be enabled or disabled by Pressing the “Hot Standby” button to toggle between <Yes> and
<No>. The boiler overview and firing rate screens will indicate when the boiler is in hot standby.

Hot Stand-By can be initiated manually by pressing <Force Hot Standby> on the Firing Rate screen. The
boiler will remain in standby until the button is again pressed.

See Section 5 - Commissioning for more on Hot Standby.

4-20 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

Overview - Hot Standby Force Hot Standby

Figure 4-20. Hot Standby

Outdoor Temperature Reset (Hot Water units only) With

outdoor

temperature
required on Analog Input 2.2
Input 2.2 outdoor

will be applied to the operating set point. An outdoor

for

this feature. When the outdoor

temperature

is displayed on

the

this

option selected, a correction based on the

temperature

boiler overview

screen

temperature

transmitter is

is selected for Analog

.

Figure 4-21. Options

When Outdoor Reset is selected, the outdoor temperature and water temperature setpoints should be entered
from the Setpoints screen (See Section 5.5 - Setpoints) after system configuration is completed.

Combustion Air Temperature

The Combustion Air Temp Sensor transmits a 4-20mA signal to the controller. The Combustion Air Temp signal
is used in the boiler efficiency calculation, and is displayed on the Boiler Overview screen. Analog input
module required (Slot 7).

Part No. 750-366 4-21

Section 4 — System Configuration Hawk 1000

Boiler Information

The customer name, boiler ID, and boiler serial number and can be entered. This information is displayed on
the System Information Screen. To enter this information, press the text display button beneath the
description. An alphanumeric keypad pop-up window appears.

Figure 4-22. Boiler information

Once all the information is entered, press the carriage return button. The Boiler ID and Serial Number are each
limited to 20 characters, including spaces.

If a Master Panel is being used in this system the customer name, boiler ID, and boiler serial number must be
entered again in order for this information to appear on the Master Panel HMI

Auxiliary Alarm 1-3

If the system has auxiliary alarms the text that is displayed when the alarm is triggered can be entered. To
enter this information, press the text display button beneath the description. An alphanumeric keypad pop-up
window appears.

Once all the information is entered, press the carriage return button. The auxiliary alarms are each limited to
20 characters, including spaces.

Auxiliary alarm 1 must be wired to Slot 1 Input 13

Auxiliary alarm 2 must be wired to Slot 1 Input 14

Auxiliary alarm 3 must be wired to Slot 1 Input 15

For example: If Auxiliary Alarm 1 is entered as Low Water Flow and Discrete Input I:1.13 is “On” the alarm
displayed on the HMI for Auxiliary Alarm 1 will read “Aux 1 - Low Water Flow”.

4-22 Part No. 750-366

Hawk 1000 Section 4 — System Configuration

Figure 4-23. Aux inputs

4.4.9 Configuration Summary

Once the System Configuration settings have been entered the entries can be viewed from the System
Configuration Summary screens.

Note: The “Confirm Options” push button is only visible if this is a new system configuration or a system
configuration parameter marked with an asterisk has been changed.

Page 1 Page 2

Figure 4-24. Configuration summary

To complete system configuration, press the <Confirm Options> pushbutton on the Options Summary Screen.

The Configuration selections may be changed after the HAWK 1000 is installed. However, for many of the
options, additional hardware is required to make the function work. Please refer to the parts section for the
required hardware.

Part No. 750-366 4-23

Section 4 — System Configuration Hawk 1000

4-24 Part No. 750-366

Section 5

Commissioning

Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Setting Combustion - Parallel Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Store Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Store Lightoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Curve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

No VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Setting Combustion - Low/High/Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Alarms and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Low O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Low Steam Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Mod. Rate Limiter, Max. O2 Correct, Remote Shutdown by Comms. . . . . . . . . . . . . 5-12

Stack Low Temp. Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Operating Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Outdoor Temperature Reset (Hot Water only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

Revert to Pilot (CB 120E only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Drive Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Ethernet Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Two Boiler Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17

Thermal Shock Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

www.cleaverbrooks.com

Section 5 — Commissioning Hawk 1000

5.1 Commissioning the Actuators

When system configuration is complete, the <Calibrate Actuators> button will be available on the Main
screen and will indicate “Required”.

Figure 5-1. Actuator calibration required

Press <Calibrate Actuators> for the Actuator Commissioning screen, where air, fuel, and FGR actuators can
be individually selected for commissioning. On this screen, press <Commission Actuator> for the desired
actuator and read the warning screen which follows. In this example we will be commissioning the air
actuator.

Actuator Commissioning Screen

Warning

Figure 5-2. Actuator commissioning

NOTE: Any combustion curves previously stored for the current fuel will be erased once the actuator
commissioning process has begun. Press <Enable Air Actuator Commissioning> on the warning screen to

continue.

First select the direction of rotation of the actuator shaft. This is the direction of rotation to open the actuator
when looking at the actuator from the perspective of the actuator circuit board (or circuit board cover).

5-2 Part No. 750-366

Hawk 1000 Section 5 — Commissioning

Figure 5-3. Actuator rotation

The default direction of rotation is counterclockwise for air and all fuels, and clockwise for FGR.

This screen also indicates the actuator torque rating (read via Modbus by the PLC).

Press <Next> after confirming the actuator direction of rotation. Next store the open and closed positions of
the actuator. Using the <Actuator Close (Open)> buttons, move the actuator to its fully open or closed
position (either position may be stored first). With the actuator fully open (closed), press <Store Open
(Close)>.

Figure 5-4. Actuator stroke

Note: CCW rotation means the closed position will be greater than the open position.

CW rotation means the open position will be greater than the closed position.

The actuator position is given in units of degrees x 10.

Valid range is 0 - 1100 units (0-110 degrees). Open and closed positions must be greater than 100 units (10
degrees) apart. If these conditions are not met, a “Configuration Invalid” error will result, and reconfiguration
of the actuator will be required.

When valid data have been entered, the <Save Air Actuator Configuration> button will appear. Press to save
data, then press <Next Actuator> and repeat the above steps.

Part No. 750-366 5-3

Section 5 — Commissioning Hawk 1000

Invalid Data

Save Data

Figure 5-5. Verify actuator calibration

5.2 Setting Combustion - Parallel Positioning

When actuators for the currently selected fuel have been calibrated, the <Set Combustion> button will be
available on the Main screen. To begin the procedure, press <Set Combustion> and observe the warning that
follows.

Main Screen

Warning

Figure 5-6. Begin combustion setup

Press <I READ THE WARNING - I AM QUALIFIED> to continue. An
additional warning screen will appear, notifying the user that the
boiler Operating Limit Relay will be de-energized during combustion
setup.

Press <Confirm Combustion Setup> to continue.

2nd Warning

5-4 Part No. 750-366

Hawk 1000 Section 5 — Commissioning

5.2.1 Store Purge

The first step is to store the Purge position. A help screen is available to guide the user through storing the
Purge (and Lightoff) positions:

Figure 5-7. Purge/Lightoff help

For a valid Purge position the air actuator must be greater than 80% open. To position the actuators in setting
combustion, first press the button for the desired actuator on the Combustion Setup screen.

Press to
adjust
actuator

Figure 5-8. Combustion Setup

Next, use the <Dec> and <Inc> buttons to move the air actuator to the desired position.

Part No. 750-366 5-5

Section 5 — Commissioning Hawk 1000

Figure 5-9. Adjust actuator

When purge position is set, press <Store Purge>. When prompted with “Store Current Values?”, press <Store
Purge> again to confirm or <Cancel> to re-adjust.

Figure 5-10. Store Purge

Note: If a VFD is present, the VFD purge value is automatically set at 100%.

5.2.2 Store Lightoff

When the purge position has been set, the <Store Lightoff> button will be available on the Combustion Setup
screen. After positioning the actuators in the lightoff position press <Store Lightoff>. A confirmation prompt
will appear as when storing the purge position. When both purge and lightoff have been set, the <Curve
Setup> button will be available.

All values except VFD must be less than 25% to store lightoff.

5-6 Part No. 750-366

Hawk 1000 Section 5 — Commissioning

Figure 5-11. Store Lightoff

5.2.3 Curve Setup

A help screen is available to guide the user through the steps of setting the combustion curve:

Figure 5-12. Combustion setup help

To set the combustion curve, the burner must be on. If all conditions to start the boiler have been met, the
<Burner Start> pushbutton will appear on the Combustion Setup screen. Press <Burner Start>; the purge
sequence will run and the actuators will return to the lightoff position. Press <Lightoff>. The Flame Safeguard
will sequence through pilot trial and main flame and the burner will ignite. The actuators can now be
positioned for the first point.

• 8 points minimum must be stored for a valid curve (16 maximum allowed)

• Points can not be skipped

• Values for Air and Fuel Actuator 1 must be greater than previous values for a valid point to be stored.

• Pressing <New Profile> at any time will erase the current curve.

• When the combustion curve is complete (8 valid points are stored) the <Firing Rate> button will appear,
replacing the <Main> button.

• Pressing <Pt Adv Enable> will allow stepping through the combustion curve using <Next> and <Prev>.
With Points Advance disabled, the actuators will not move when <Next> or <Prev> is pushed.

Part No. 750-366 5-7

Section 5 — Commissioning Hawk 1000

Figure 5-13. Combustion curve complete

5.3 Setting Combustion - Single Point Positioning

5.3.1 VFD or O2 Trim

If VFD or O2 Trim is selected, combustion setup is identical to parallel positioning, with the exception that
only the air actuator will be active. 8 points minimum are required for the combustion curve, with 16 points
maximum.

5.3.2 No VFD or O2 Trim

The combustion curve consists of 2 points. Only the air actuator will be active. Point 1 will be low fire; Point
2 will be high fire.

5.4 Setting Combustion - Low/High/Low

Low/High/Low combustion is only available with Cleaver-Brooks Model 4/Model 5 boilers.

Low/High/Low is only available for Oil (as Fuel 2). The combustion curve consists of 2 points; only the air
actuator is active. Point 1 will be low fire; Point 2 will be high fire.

A View/Adjust Setpoints screen is provided.

Figure 5-14. View/Adjust Setpoints

When using Low/High/Low combustion the boiler firing rate will be either 0% or 100%. The oil valves open
and close based on the air actuator feedback percent. The high fire and low fire setpoints are limited by the
Boiler On and Boiler Off points.

5-8 Part No. 750-366

Hawk 1000 Section 5 — Commissioning

When steam pressure is greater than the low fire point, the firing rate will go to 0%.

When steam pressure is less than the high fire point, the firing rate will go to 100%.

5.5 Firing Rate Screen

From the Firing Rate screen the boiler controls can be toggled between manual and automatic operation. With
<Manual> selected, the actuators will remain in their current positions until moved manually by the operator
using the Control Output <Decrease> and <Increase> buttons.

Figure 5-15.

In Automatic mode, control output is based on demand; the actuators will be positioned according to the
currently active combustion curve.

While in Automatic the boiler can be forced to low fire by isolated 120VAC contact signal on digital input
I:5.4. The boiler will remain at low fire until this signal is removed.

Figure 5-16.

The Firing Rate screen also allows selection of Remote Setpoint or Remote Modulation for interfacing with a
Building Management System or other control system.

Part No. 750-366 5-9

Section 5 — Commissioning Hawk 1000

Figure 5-17.

In the event of a bad remote signal, an alarm message will appear on the screen and the control will revert to
Local/Auto mode.

The <Adjust Gains> button accesses the system PID tuning. Default values are: P=5, I=5, D=0.

Figure 5-18. Adjust Gains

<Adjust Setpoint> allows adjustment of Setpoint 1 and Setpoint 2 (if dual setpoint is configured).

Figure 5-19. Adjust Setpoint

<View Actuator> shows setpoint and feedback signals for all configured actuators.

5-10 Part No. 750-366

Hawk 1000 Section 5 — Commissioning

Figure 5-20. View Actuators

The <Manipulate Actuators> button allows the actuators to travel through 0-100% of firing rate to verify all
actuators are positioning correctly at the current firing rate. To use this feature, the Burner Switch must be
OFF and firing rate must be in MANUAL mode. While manipulating the actuators, output and firing rate are
not rate limited.

5.6 Alarms and Limits

Alarms with configurable parameters and firing rate/setpoint limits can be edited from this screen.
Configurable items include the following:

5.6.1 Low O2

Select Low O2 Alarm, Shutdown, and Alarm Delay points. Low O2
Alarm only available with selection of an O2 analyzer. Shutdown only
available if selected in configuration menu.

5.6.2 Low Steam Pressure

Select Low Steam Pressure setpoint and Audible Yes/No. Alarm horn
or bell must be available for audible alarms.

Figure 5-22. Alarms and Limits - Low Steam Pressure

Figure 5-21. Alarms and Limits - Low

O2

Part No. 750-366 5-11

Section 5 — Commissioning Hawk 1000

5.6.3 Mod. Rate Limiter, Max. O2 Correct, Remote Shutdown by Comms.

Modulation rate limiting increases/decreases the rate of change of firing rate output. The value entered is the

number of seconds the control output will take to go between 0-100%

Maximum O2 Trim Correction is the

maximum).

value plus or minus that the VFD or Air Actuator can correct (+/- 10%

Remote Shutdown by Communications allows for remote start/stop of the boiler. If this feature is enabled, the
<On Comms Failure...> setting determines what the boiler will do upon a failure of remote communications
(shut down or remain in its last state).

5.6.4 Stack Low Temp. Hold

This feature is only available with FGR. Selectable to hold FGR only (20 ppm or less) or FGR and firing rate.

“FGR Posn w/ Low Stk Temp” must be set for every combustion curve (4 maximum) and must be lower than
the FGR low fire point.

If Stack Low Temp. Hold is enabled and the stack temperature is below the “Stack Low Temp Hold” setpoint,
the boiler is allowed to modulate while the FGR actuator is forced to the “FGR Posn w/Low Stk Temp” position.
When the stack temperature rises above the setpoint for the “Delay Seconds” period, FGR will release and go
to the firing rate commanded position.

5-12 Part No. 750-366

Hawk 1000 Section 5 — Commissioning

5.7 Setpoints

5.7.1 Operating Setpoint

Figure 5-23. Operating Setpoint

Steam Pressure (Water Temperature) setpoint and on/off differential are set here. If dual setpoint is selected,
the Operating Setpoint 2 can be entered from the HMI but the ON/OFF points are calculated using the same
dP/dT as Setpoint 1.

Set Point = steam pressure (water temperature) operating setpoint

On Point = Set Point + (On dP% x Set Point)/100. Valid entries for On dP are from -50% to Off dP%.

Off Point = Set Point + (Off dP% x Set Point)/100. Valid entries for Off dP are from On dP% to the calculated
value where Off Point is not greater than the Safety Valve setpoint.

5.7.2 Outdoor Temperature Reset (Hot Water only)

If Outdoor Reset was selected during system configuration, the desired setpoints should be entered here.

Figure 5-24. Outdoor Reset screen

Hot Standby when active will cycle the boiler on if the shell water temperature drops 5 degrees F below the
“Hot Standby Temp”. The boiler will remain at low fire until the shell water temperature reaches the “Hot
Standby Temp” at which time the boiler will turn off. I:5.7 ALFCO must be turned off to initiate Hot Standby.

Hot Standby can be initiated manually by pressing <Force Hot Standby> (on the Firing Rate Screen).

Part No. 750-366 5-13

Section 5 — Commissioning Hawk 1000

OUTDOOR RESET CURVE

Set point is linear in relation to the outdoor temperature.
Range for outdoor temperature transmitter is 4 ma = -50 deg F, 20 ma = 900 deg F.
In this example:
Outdoor Temp Range Low = 0 deg F

Set Point Range High = 200 deg F
Outdoor Temp Range High = 60 deg F
Set Point Range Low = 180 deg F

205

200

195

Setpoint

Outdoor

Temperature

190

185

180

175

-60 -40 -20 0 20 40 60 80

Figure 5-25. Outdoor reset curve

5.7.3 Revert to Pilot (CB 120E only)

Revert to Pilot (RTP) reduces cycling by eliminating the purge sequence.

When RTP is initiated the boiler returns to low fire, output O:6.4 is energized, and the Revert to Pilot signal
is sent to the flame safeguard. The RTP sequence is managed by the FSG: pilot is energized, and upon proof
of pilot the main gas valve de-energizes and the boiler remains on pilot. When demand returns or digital input
J:5.7 is ON the main gas valve is energized.

When RTP is on a “Rev to Pilot” indicator will appear on the Overview and Firing Rate screens.

Initiated by process variable

If ‘Initiate by process variable’ is selected, Revert to Pilot is initiated when steam pressure is greater than or
equal to “Revert to Pilot Pressure” and de-activated when steam pressure is below the boiler “On Point”.

Revert to Pilot Pressure = Off Point - (Revert to Pilot dP% x Off Point) [ensures that the RTP setting is always
less than or equal to the boiler off point]

5-14 Part No. 750-366

Hawk 1000 Section 5 — Commissioning

Revert to Pilot Pressure must be greater than the boiler operating Setpoint or boiler On Point, whichever is
greater.

Figure 5-26. Revert to Pilot

Initiated by digital input

If ‘Initiate by digital input’ is selected, the above screen will not be shown; Revert to Pilot will be initiated when
digital input I:5.7 ALFCO is OFF.

5.8 O2 Trim

If O2 Trim was selected and an analyzer specified during system configuration, the <Flue Gas O2 Control>
button will appear on the Main screen.

Figure 5-27.

O2 Trim is accomplished by means of the air actuator, or by the VFD if present (if VFD is in Bypass, the air
actuator is used). A manual operating mode is provided for diagnostic or testing purposes.

The CB O2 analyzer requires calibration on power up, or if one week has elapsed since the last calibration. If
using the Yokogawa analyzer, the PLC will expect a “Sensor OK” input from the analyzer at input I:5.2.

Once the O2 sensor is calibrated or “Sensor OK” input is on, the O2 setpoint is captured when setting
combustion curves.

PID control of O2 Trim is provided. Values can be adjusted by pressing <Adjust Gains>. Defaults are P=3,
I=5, and D=0.

Part No. 750-366 5-15

Section 5 — Commissioning Hawk 1000

5.9 Drive Data

If a VFD is present, <Drive Data> will display a read-only screen showing drive output and feedback, Low/
High/Lightoff settings, and current running frequency.

5.10 Ethernet Configuration

Multiple boilers on the same Ethernet network require unique IP addresses. To change a boiler’s configuration,
press the desired field in the “Set New Ethernet Configuration” area. If user is logged in at the proper level, a
numeric keypad will appear. Enter the new data and press the enter key (or use the PV+ keypad). When
finished, go to <Set Enet Config> and when prompted with “Set PLC Ethernet Port Configuration?” press
<Yes>.

Figure 5-28.

After setting a new Ethernet configuration, communication between the HMI and PLC will be lost and must
be reestablished from the HMI. For more information, see “Procedure to Load and Setup a PV+” (available
on the CB portal).

5-16 Part No. 750-366

Hawk 1000 Section 5 — Commissioning

5.11 Two Boiler Lead Lag

The Hawk 1000 uses dual setpoints to accomplish “Lead Lag” control in a two boiler control scheme. The
setpoints are based on each boiler's local steam pressure (for steam boilers). The “Master” boiler has a selector
switch, which designates each of the two boilers as lead, or lag. There are two contacts for the two position
selector switch.

Dual set point option via digital input must be selected when unit is being configured.

The first contact is used to provide a digital input to Boiler #1 PLC (I: 5/14) to designate this boiler as the
lead boiler. The second contact of the selector switch is used to provide a digital input to Boiler #2 PLC (I:5/

14) to designate Boiler #2 as the lead boiler. With input energized set point 2 is selected. Set point 2 is

designated for the boiler operation when it is selected as lag unit.

This selection dictates which of the boilers will be using set-point #1 and which will use set-point #2. The
two boilers will then start and stop, based on those set-points. These set-point values are set in the panel view
screen. It is important to set the set point 1 higher then set point 2.

The Hawk 1000, however, will not perform unison modulation. The Hawk 1000 does not use a header steam
pressure (or hot water temperature) transmitter for lead lag controls, just the local steam pressure (or hot water
temperature) transmitter on the boiler.

Figure 5-29. Dual Setpoint, Dual SP Signal Select

Figure 5-30. 2 boiler lead lag wiring, typical

Part No. 750-366 5-17

Section 5 — Commissioning Hawk 1000

5.12 Thermal Shock Routine

Steam boilers

Thermal shock protection is activated when actual water temperature is below 60% of the steam saturation
temperature at set point. Maximum limit for CV for PID is based on water temperature and is determined by
function. If boiler in thermal shock protection and release for modulation from FSG is true and water
temperature is above setting of hot standby off temperature*, thermal shock override timer is activated.
Thermal shock override timer is set for 126 seconds. Done bit of this timer resets the timer and increments
thermal shock override counter. Accumulated value of the counter is compared to the function generator
output and highest value is selected as maximum limit for CV. Every time thermal shock rung becomes true
output value from function generator is moved to the counter accumulated value. Thermal shock routine is
deactivated when hot water temperature reaches 90% of the saturated temperature at set point. It will not be
activated until temperature drops below 60% with fuel valve terminal de-energized. If fuel valve has been
de-energized for more than 8 hours, thermal shock protection is activated.

For Hot Water Boilers

Thermal shock protection is activated when actual water temperature is below minimum temperature (150F
for Firetube 120F for FLX) Maximum limit for CV for PID is based on water temperature and is determined by
function generator. If boiler is in thermal shock protection and release for modulation from FSG is true and
water temperature is above setting of hot standby off temperature*, thermal shock override timer is activated.
Thermal shock override timer is set for 60 seconds. Done bit of this timer resets the timer and increments
thermal shock override counter. Accumulated value of the counter is compared to the function generator
output and highest value is selected as maximum limit for CV. Every time thermal shock rung becomes true
output value from function generator is moved to the counter accumulated value. Thermal shock routine is
deactivated when hot water temperature reaches 90% of set point. It will not be activated until temperature
drops below minimum temperature with fuel valve terminal de-energized. If fuel valve has been de-energized
for more than 8 hours, thermal shock protection is activated.

*If fuel valve is energized for more than 1 hour (Steam) or 10 minutes (Hot Water) and water temperature is still below standby
temperature setting. Firing rate will start ramping up as described.

5-18 Part No. 750-366

Section 6

Diagnostics and Troubleshooting

System Monitoring and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Burner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

PLC Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Diagnostic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

PLC Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

www.cleaverbrooks.com

Section 6 — Diagnostics and Troubleshooting Hawk 1000

6.1 System Monitoring and Diagnostics

6.1.1 Boiler Overview

The Hawk 1000 has a number of features for monitoring system performance and diagnosing problems.

The Boiler Overview screen shows the primary operating details of the boiler and is accessible from the Main
screen.

Figure 6-1. Overview screen

6.1.2 Burner Control

The Burner Control screen gives details on the installed Flame Safeguard (CB780 or CB120).

Burner Control - CB780

Burner Control - CB120

Figure 6-2. Burner Control screens

The status of the Flame Safety control is shown as well as the status of the inputs that allow the boiler to start.

The following flame safety status and boiler inputs are shown on the Burner Control screen:

Burner Switch - Indicates position of the burner switch.
Load Demand - When starting the boiler, there is a load demand if the system pressure (steam) or temperature

(hot water) is below the “On Point”. When system Pressure/Temperature exceeds the OFF point, “No Demand”

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Hawk 1000 Section 6 — Diagnostics and Troubleshooting

is indicated. When the system Pressure/Temperature drops below the “On Point”, load demand will again be
displayed.

Limits -This is an indication of the status of the running interlocks on the boiler.
External Interlock - Feedback input from external interlock. When there is a load demand, and the burner

switch and limits are closed, the HAWK 1000 has isolated contacts (2.5A @ 125VAC) for output to an
external interlock device (e.g. fresh air damper, circulating pump). The boiler will start once the external
interlock is proven.

Note: The external interlock must be jumped if not used

ALFCO - Assured Low Fire Cut-Off. An external isolated start-stop contact can be provided to shut down the

boiler. This contact will drive the boiler to low fire prior to shut down.
Note: The ALFCO must be jumped if not used.

6.1.3 System Information

Press <System Information> from the Main screen to access. This screen shows boiler identification
information, the currently loaded programs for the PLC and HMI, elapsed time and cycles since last startup,
and network address information.

Figure 6-3. System Information

6.1.4 PLC Info

Figure 6-4. PLC Info

This screen duplicates the L24 Status LEDs and in addition shows the current PLC firmware revision, serial
number, and PLC keyswitch position.

Part No. 750-366 6-3

Section 6 — Diagnostics and Troubleshooting Hawk 1000

6.1.5 Diagnostic Screens

Press <Diagnostic> on the Main screen for the diagnostic screen menu. Select an item from the menu to
show a detailed view of the corresponding program logic. Items in green are TRUE and those in white are
FALSE.

Figure 6-5. Diagnostics screen

6.2 PLC Status

The L24E has a bank of multi-state LEDs to indicate the controller’s operating
status and communication activities. See tables below.

Table 1: PLC Status LEDs

Indicator Status Description

RUN Off The controller is in Program or Test mode.

Green The controller is in Run mode.

FORCE Off No tags contain I/O force values. I/O forces are inactive (disabled).

Yellow I/O forces are active (enabled). I/O force values may or may not exist.

Flashing yellow One or more input or output addresses have been forced to an On or Off condition, but the forces have

not been enabled.

I/O Off The controller does not contain a project.

Green The controller is communicating with all of the devices in its I/O configuration.

Flashing green One or more devices in the I/O configuration of the controller are not responding.

Flashing red One of the following conditions exists:

• The controller is not communicating with any devices.

• A fault has occurred on the controller

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Hawk 1000 Section 6 — Diagnostics and Troubleshooting

Table 1: PLC Status LEDs (Continued)

OK Off No power is applied.

Green The controller is OK.

Flashing green The controller is storing a project to or loading a project from the SD card.

Red The controller detected a nonrecoverable major fault and cleared the project from memory.

Flashing red One of the following:

• The controller requires a firmware update.

• A major recoverable fault occurred on the controller.

• A nonrecoverable major fault occurred on the controller and cleared the program from memory.

• A controller firmware update is in process.

Dim green to red Save to Flash at power-down.

Table 2: PLC Communication LEDs

Indicator Status Description

Ethernet Network
Status (NS)

Ethernet Link Sta­tus (LINK 1/LINK 2)

SD Card Activity
(SD) Status

Off The port is not initialized; it does not have an IP address and is operating in BOOTP or DHCP

mode.

Green The port has an IP address and CIP connections are established.

Flashing green The port has an IP address, but no CIP connections are established.

Red The port has detected that the assigned IP address is already in use.

Flashing red/green The port is performing its power-up self test.

Off One of the following conditions exists:

• No link.

• Port administratively disabled.

• Port disabled because rapid ring fault condition was detected (LINK2).

Green One of the following conditions exists:

• A 100 Mbps link (half- or full-duplex) exists, no activity.

• A 10 Mbps link (half- or full-duplex) exists, no activity.

• Ring network is operating normally and the controller is the active supervisor.

• Ring network has encountered a rare partial network fault and the controller is the active
supervisor.

Flashing green One of the following conditions exists:

• A 100 Mbps link exists and there is activity.

• A 10 Mbps link exists and there is activity.

Off There is no activity to the SD card.

Flashing green The controller is reading from or writing to the SD card.

Flashing red The SD card does not have a valid file system.

Part No. 750-366 6-5

Section 6 — Diagnostics and Troubleshooting Hawk 1000

6-6 Part No. 750-366

Section 7

Parts

PLC, I/O, HMI

Qty Part Number Description

1 880-06082-000 Hawk 1000 Kit - must be ordered as complete kit only

1 833-10039-000 PLC Processor

1 833-10040-000 4 Inch PV+ Compact Touch Screen with (118-04514-000 label included)

1 833-02842-000 Digital Input Module

1 833-02872-000 Relay Module

1 833-03099-000 Modbus Module SM2

2 826-00111-000 Ethernet Cable

1 832-02404-000 Power Supply120 Watt, (For PLC, PV + & Analog Inputs)

1 832-02037-000 Power Supply 50 Watt (For Modbus) Use 120 Watt for 50NM Actuator

1 848-01623-000 Centre 60x30x10, No Cut outs (Conversions uses a different size)

1 983-00083-000 6 Amp

1 836-00620-000 Qty 1 (add another if oil heater for #6 oil is required)

1 118-03173-000 4” x 16”

1 001-01476-000 Orion, OA109-12POT/DIN

1 817-00239-000 Alarm Bell

ACTUATORS

Qty Part Number Description

1 945-00259-000 Modbus FX04-1, 3 ft-lb (4 N-m)

(Use on Fuel and FGR valves, except in High Torque applications)

1 945-00260-000 Modbus FX20-1, 15 ft-lb (20 N-m)

(Use On Combustion Air Damper, except in High Torque applications)

1 945-00261-000 Modbus FX50-1, 37 ft-lb (50 N-m)

600” 826-00205-000 Cable, 5 conductor,18 AWG

826-00206-000 Connector, female, straight, 7/8” screw connection - Two required per actuator

www.cleaverbrooks.com

Section 7 — Parts Hawk 1000

MISC.

Qty Part Number Description

1 833-02835-000 1769-IF4 Analog Current Input Module (req. w/ O2 Trim, VFD, or Combustion Air Temp option)

1 833-10116-000 9300-ENA Ethernet Appliance Router

1 817-05166-000 Temperature Sensor, 8" Probe, -50-900 Deg F

1 833-09181-000 Ethernet Switch, Rockwell Stratix 5 Port, 1783-US05T

1 833-09163-000 Ethernet Switch, Rockwell Stratix, 8 Port, 1783-US08T

1

1 817-05166-000 Temperature Sensor, 8" Probe, -50-900 Deg F

1 008-02998-000 Transmitter mounting, Outdoor Reset

1 836-00627-000 Bundled Kit - Gas Oil Selector

FSG

Qty Part Number Description

880-02117-000 CB-780E w / IR Scanner Kit

1 833-03517-000 CB-780E Programmer

1 833-02725-000 Wiring Sub-Base

1 833-03495-000 Infared Amplifier

1 833-02730-000 Purge Timer Card

1 817-04133-000 Scanner IR 817-1742

880-02118-000 CB-780E w / UV Scanner Kit

1 833-03517-000 CB-780E Programmer

1 833-02725-000 Wiring Sub-Base

1 833-02724-000 U.V. Amplifier

1 833-02730-000 Purge Timer Card

1 817-01743-000 Flame Detector UV

880-02097-000 CB-120E w / IR Scanner Kit

1 833-03708-000 Chassis/Amplifier

1 833-03153-000 Wiring Sub-Base open with terminal block

1 833-03143-000 Programmer

1 833-03151-000 Display

1 833-03516-000 ED-512 communications cable 4 foot long

1 817-01933-000 IR Scanner 817-2261

880-02096-000 CB-120E w / UV Scanner Kit

1 833-03135-000 Chassis/Amplifier

1 833-03153-000 Wiring Sub-Base open with terminal block

1 833-03143-000 Programmer

1 833-03151-000 Display

1 833-03516-000 ED-512 communications cable 4 foot long

1 817-02262-000 UV Detector

7-2 Part No. 750-366

Hawk 1000 Section 7 — Parts

STEAM TRANSMITTERS

Qty Part Number Description

1 817-04866-000 E&H PMC131-A22F1Q4H

1 817-00001-000 E&H PMC131-A22F1Q4N

1 817-04867-000 E&H PMC131-A22F1Q4R

1 817-04868-000 E&H PMC131-A22F1Q4S

1 817-04869-000 E&H PMC131-A22F1Q4T

Steam Transmitters (Optional)

1 817-04873-000 PMP51-1CQW9/0 (includes Isolation Valve)

1 817-00002-000 PMP51-1R5E5/0 (includes Isolation Valve)

1 817-04874-000 PMP51-1JAN0/0 (includes Isolation Valve)

1 817-04875-000 PMP51-E9K7/115 (includes Isolation Valve)

1 817-04876-000 PMP51-E9K7/101 (Specify Range) (includes Valve)

1 817-04877-000 PMP51-E9K7/139 (Specify Range) (includes Valve)

1 817-04878-000 PMP51-E9K7/125 (Specify Range) (includes Valve)

1 817-09768-000 PMP51-E9K7/142 (includes Isolation Valve)

1 817-05167-000 E&H, TH13-1A13X1BBA1AK, NON HART, 2.5" Thermowell, -50-900 Deg F

1 817-05166-000 E&H, TH11-B8CBBA1AK4, NON HART, 8" Probe, -50-900 Deg F

HOT WATER

Qty Part Number Description

1 817-09776-000 4.5" Thermowell, Range +50 -300 F

1 817-09777-000 4.5" Thermowell, Range -50 -900 F

1 817-09778-000 4.5" Thermowell, Range +50 -500 F

1 817-09777-000 4.5" Thermowell, Range -50 -900 F

O2 TRIM

Qty Part Number Description

O2 Monitoring Only or Air Trim

1 985-00130-000 O2 Probe and Analyzer

1 656-07576-000

1 817-05166-000 E&H, TH11-B8CBBA1AK4, NON HART, 8" Probe, -50-900 Deg F

622-00027-000 O2 Monitoring Only or Air Trim

1 880-01847-000 ECM controller with NTK Wide Band Sensor and Cable Harness

1 817-05166-000 E&H, TH11-B8CBBA1AK4, NON HART, 8" Probe, -50-900 Deg F

1 040-00735-000 O2 Sampling Probe Housing Assembly

1 832-02404-00 O2 Trim Power Supply120 Watt

Part No. 750-366 7-3

Section 7 — Parts Hawk 1000

7-4 Part No. 750-366