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.
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