hawk 4000 -...

750-34201/2016

Hawk 4000Boiler Control

Operation Manual

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 con-tents carefully. The unit will provide good service and continued operation if proper operating and maintenance instruc-tions 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-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical 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 attendants of their responsibilities. Such features merely eliminate certain repetitive chores, allowing more time for the proper upkeep of the equipment.

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 at-tempting 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 regula-tions of the 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 pro-ceeding.

Cleaver-BrooksHAWK 4000 Boiler Control

Operation Manual

Manual Part No. 750-34201/2016

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

Printed in U.S.A.

CONTENTSSection 1General

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Hawk 4000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

New Features 2016. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Safety Provisions and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Burner Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

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

Section 2System Components

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2PLC Rack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Human-Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Steam Systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Hot Water systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Section 3Hardware Setup

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2DIN Rail Latch and Expansion I/O Module Locking Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Panel and Field Wiring Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3SM2 Module DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Burner Control Modbus Address and Baud Rate - CB780E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Burner Control Modbus Address and Baud Rate - CB120E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6PLC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Modbus Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Setting The Modbus Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Power/ Communications LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Moving The Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Section 4System Configuration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Logging in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Configuration Screen #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Boiler Media and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Fuel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Actuator Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Configuration Screen #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Variable Frequency Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Configuration Screen #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Economizer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Feedwater Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17Feedwater Level Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Configuration Screen #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20Remote Modulation/Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20Dual Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22Hot Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Configuration Screen #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Configuration Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24Auxiliary Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Aux Analog Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25VFD Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26Email Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

SMTP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32Text/Email Contact List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

PanelView Plus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33Installing a PV+ Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33Change the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39Viewing the PV+ Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Section 5Commissioning

Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2Setting Combustion - Parallel Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Store Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5Store Lightoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7Curve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9No VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Combustion Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10Tuning and Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12Alarms and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

Operating Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16Outdoor Temperature Reset (Hot Water only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16Hot Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

Revert to Pilot (CB 120E only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18Mix O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19Drive Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5-19Two Boiler Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20

Lead Lag Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21Lead Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

Thermal Shock Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23Two-Stage Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24

Section 6Diagnostics and Troubleshooting

System Monitoring and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Burner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2System Information/PLC Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Modbus diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4PLC Output Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4PLC Hardware Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5PLC I/O Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7PLC Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Fault List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Section 7Parts

APPENDIX A — HAWK 4000 MASTER TAG LIST

APPENDIX B — LOADING A PLC PROGRAM

www.cleaverbrooks.com

Section 1General

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Hawk 4000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

New Features 2016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Safety Provisions and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Burner Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

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

Section 1 — General Hawk 4000

1.1 IntroductionThe Cleaver-Brooks HAWK 4000 is an exclusive Boiler Management and Control system specifically designedto integrate the functions of a Programmable Boiler Controller and Burner Management Controller, as well asother boiler operating and ancillary controls. The HAWK 4000 system incorporates a user-friendly, graphicalHuman Machine Interface (HMI) that displays boiler parameters, fault annunciation and alarm history, as wellas providing access to boiler configuration and control functions.

Figure 1-1. Boiler Overview Screen

Figure 1-2. Typical Panel Layout

1. (Slot 0) - PLC L33ER2. (Slot 1) - Modbus Module SM23. Power supply4. (Slot 2) - Digital Inputs5. (Slot 3) - Digital Outputs6. (Slot 4) - Analog Inputs7. (Slot 5) - Analog Outputs8. (Slot 6) - Analog Inputs9. (Slot 7) - Digital Inputs*10. (Slot 8) - Analog Inputs*11. (Slot 9) - Analog Outputs**optional

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Hawk 4000 Section 1 — General

1.2 System DescriptionThe HAWK 4000 Boiler Control System provides boiler firing rate control to maintain steam pressure (or hotwater supply temperature) at set point. Final control element(s) are controlled via Modbus communicationsnetwork to insure that the optimum fuel/ air ratio is maintained throughout the firing range.

The Hawk 4000 supports three fuel types. Fuel/air ratio is controlled using either parallel positioning or single-point control method.

The Hawk 4000 can be monitored by Building/ Plant Automation Systems via an optional CB ProtoNodeprotocol translator. Ethernet / Internet communication also enables remote monitoring of the Hawk 4000Boiler Control System (additional software and/or hardware required).

The HAWK 4000 may be used on most types of steam and hot water boilers, including firetube, industrialwatertube, and commercial watertube. In addition to installation on new boilers, the HAWK 4000 can beadded 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:

Level Master - 750-281

ProtoNode Gateway communication interface - 750-361

CB120E Burner Control - 750-264

CB780E Burner Control - 750-234

Variable Frequency Drives - 750-198

O2 Trim - 750-224

Draft Control - 750-221

Economizers (Single Stage and Two-Stage) - 750-266

Master Panel - 750-375

Part No. 750-342 1-3


1.3 Hawk 4000 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.)• 7” color touchscreen Human Machine Interface (HMI); 10” screen optional• 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)• Remote modulation or remote set point• Return Temp monitor or Outdoor reset (hot water boilers)• Remote Modulation or 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• Ethernet communications• Two firing modes: Parallel or Single-point• Revert to Pilot control function (requires CB120E burner control)• Supports control of a flue gas recirculation (FGR) damper• Supports up to two air dampers• Supports the control of a 2nd gas actuator (up to three fuels)• 1, 2, or 3 element feedwater control (steam boilers)• OPC server software for building/plant automation system interface• Remote monitoring software• O2 monitoring and O2 trim (Option)• Mix O2 trim (Option)• Variable Speed Drive on combustion air fan (with bypass) (Option)• Combustion air temperature monitoring (option)• Analog input monitoring (up to 8 channels)• Expanded diagnostics• Email and text messaging for alarms/faults• Force Hot Standby by HMI• CB Level Master water level control interface

1.3.1 New features 2016Beginning in 2016 the Hawk 4000 platform will feature a number of enhancements, summarized below:

Systems having the new features can be identified by the following program numbers:PLC Standard Program: 98500553_000_00HMI Standard Program: 98500554_000HMI Standard Program metric units: 98500559_000

HAWK 4000 previous versions HAWK 4000 new

Slot 8 customer defined analog input 4 channels (1769-IF4) 8 Channels (1769-IF8)

Slot 9 analog output 2 channels (1769-OF2) 4 channels (1769-OF4)

Number of Fuels 2 3

Second Gas Valve 2 fuels All 3 Fuels

Second Air Damper Not Available Available

VFD Bypass Fuel 1 Only All 3 Fuels

Level Control Not Available 1, 2 or 3 element

VFD PF400, 70, 700 PowerFlex 400, 70, 700, 753

Customer Defined Analog Inputs Predefined up to 4 (minimum 1) User defined up to 8 (minimum 3)

Force Hot Standby 3-position switch HMI pushbutton

VFD feedback 0-10 VDC 4-20 mA

Single-point air actuator 4-20 mA Modbus

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Hawk 4000 Section 1 — General

1.4 Safety Provisions and Diagnostics1.4.1 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

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. FSG / Burner Control screen

CB780E

CB120E

Part No. 750-342 1-5


1.5 Inputs and Outputs

Slot 0Processor

Slot 1Modbus Card

Power Supply

Slot 2 - Digital Inputs Slot 3 - Digital Outputs Slot 4 - Analog Inputs

Address Name Address Name Address Name

I2/0 Blower Terminal O3/0 Recycle Limit (RLR) I4/0 Steam Pressure (Supply Water Temp HW)

I2/1 Purge O3/1 External Start Interlock I4/1 Water Level (ST)

I2/2 O2 Analyzer Status (Yokogawa)

O3/2 Non-Recycle Limit (NRLR)

I4/2 O2

I2/3 VFD Status O3/3 Prove Low Fire I4/3 Remote Mod/SP or 2 BLL Press (Water Temp)

I2/4 VFD Bypass O3/4 Start Slave Blr (2 Blr L-L) or Revert to Pilot *

I2/5 Ready To Start/ Limits Closed

O3/5 Prove High Fire

I2/6 Ext. Device Start Interlock (FAD)

O3/6 Alarm Output

I2/7 ALFCO or Boiler Start (L-L)

O3/7 Boiler Ready (L-L) or Revert to Pilot *

I2/8 Pilot TerminalI2/9 Main Fuel Terminal

I2/10 Fuel 1 SelectedI2/11 Fuel 2 SelectedI2/12 FSG Alarm TerminalI2/13 LWCO ShutdownI2/14 Rem. Mod/SP, DSP,

or Avail. (L-L)I2/15 Burner Switch

*With 2 boiler lead lag master boiler or if no lead lag selected, revert to pilot output is O3/7. With 2 boiler lead lag slave boiler or master panel, revert to pilot

output is O3/4.

Slot 5 - Analog Outputs Slot 6 - Analog Input Module Slot 7 - Digital Inputs Slot 8 - Analog Inputs

Address Name Address Name Address Name Address NameO5/0 VSD Control Output I6/0 Stack Temp. (b4 Econ.) I7/0 Stack Damper Open Switch

(Former I2/4)I8/0 Analog 0/Econ 2nd Stage

Temp InO5/1 Control Output LL I6/1 Comb. Air Temperature I7/1 Combustion Air Pressure High I8/1 Analog 1/Econ 2nd Stage

Temp OutO5/2 Draft Control I6/2 Water Shell (ST) Outdoor Temp

(HW)I7/2 Force to Low Fire I8/2 Analog 2/Mix O2

O5/3 Firing Rate Output/FW Valve Control

I6/3 Feed Water or Econ. Out Water Temperature (ST)

I7/3 High Limit Control I8/3 Analog 3/Steam Flow

I6/4 Stack Econ.Out (ST) Return Water Temp (HW)

I7/4 ALWCO I8/4 Analog 4/Feedwater Flow

I6/5 Economizer Temp Water IN (ST) I7/5 Low Fuel 1 Pressure/Low Oil Temp/Low F3

I8/5 Analog 5

I6/6 VFD Feedback I7/6 High Gas Pressure/High Oil Temp/High F3

I8/6 Analog 6

I6/7 Draft Signal I7/7 Low Oil Pressure I8/7 Analog 7I7/8 High Oil Pressure Optional Module - 2 Stage Econ/Mix

O2/2 or 3 FW, or aux analog inputsI7/9 Oil Drawer SwitchSlot 9 - Analog Output I7/10 Atomizing Air Pressure LowAddress Name I7/11 Combustion Air Pressure LowO9/0 Condensate Return Valve I7/12 High Water (ST) or Flow Sw. (HW)O9/1 Makeup Bypass Valve Output I7/13 Stack Damper High Pressure

Switch O9/2 Firing Rate Output for Balancing

ValveI7/14 Auxiliary #1

O9/3 Spare I7/15 Auxiliary #2 or Fuel 3 SelectedOptional module - required for 2 stage economizer

Optional Module - Required for Draft, 3rd Fuel, or expanded diagnostics

1-6 Part No. 750-342


Section 2System Components

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2PLC Rack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Human-Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Steam Systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5Hot Water systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Section 2 — System Components Hawk 4000

2-2

2.1 OverviewThe principal components of the HAWK 4000 Boiler Control System are the Programmable Logic Controller (PLC) and its associated input/output modules, the touch screen Human Machine Interface (HMI), and the Flame Safety Control. The system also includes power supplies and various relays and circuit breakers.

The HAWK 4000 Boiler Controller is factory pre-programmed to work with most Cleaver-Brooks firetube and watertube boilers, yet allows easy configuration for specific boiler applications. The Boiler Controller program logic is password secured, ensuring tamper- proof controller operation. The Touch Screen HMI provides user- friendly access to firing rate control functions, boiler diagnostics and alarm history, as well as connected operating parameters. Burner management is handled by the proven CB780E or optional CB120E Flame Safety Control.

2.2 PLC Rack ComponentsThe Programmable Logic Controller (PLC) holds the program logic and configuration data for the control system. The program logic is password-secured at the factory.

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

The Module Power Supply powers the PLC devices. The remainder of the PLC rack is for the analog and discrete input and output modules.

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

Figure 2-1. Hawk 4000 PLC Rack

Slot Module

Processor 1769-L33ER0

1

2

3

4

5

6

7

Analog Inputs 1769-IF4

Analog Outputs 1769-OF4

Analog Inputs 1769-IF8Digital Inputs [optional] 1769-IA16

8 Analog Inputs [optional] 1769-IF8

9 Analog Outputs [optional] 1769-OF4

Modbus Card 1769-SM2- Power Supply 1769-PA2

Digital Outputs 1769-OW8I

Digital Inputs 1769-IA16

1

2

3

4

5

6

7

8

9

10

11

Part No. 750-342

Hawk 4000 Section 2 — System Components

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.

Optional modules can be added to the PLC to provide additional functionality.

NOTE: The PLC program expects each device to be in a specific slot location. The HAWK 4000 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 is powered by 120VAC supply voltage and communicates with the PLC via Ethernet.

DISCRETE and ANALOG Signal TypesDiscrete 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 4000 PLC converts this current value to a range in engineering units. Example:

Steam Pressure (0-150 PSI)

Figure 2-2. Hawk 4000 HMI

Part No. 750-342 2-3


2.4 Communications2.4.1 ModbusModbus is an open serial protocol used by the HAWK 4000 system for sending and receiving control commands, position data, and diagnostic data between the PLC and attached devices. Modbus communications are managed by the SM2 module located to the right of the processor in slot 1.

HAWK 4000 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.

2.4.2 EthernetThe HAWK 4000 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

• Email or texting of boiler alarms to plant or service personnel

Ethernet/IP can also be used for control functions:

• Networking multiple boiler controllers with a single BAS interface

• Writing remote setpoint or remote start/stop of boiler

• Networking multiple boiler controllers with a Cleaver-Brooks Master Panel

2.4.3 USBUSB communications are used to connect a laptop computer to the PLC for diagnostic purposes. The HMI has 2 USB ports that may be used for file transfer.

The HMI USB ports also support keyboard and mouse input.

Figure 2-3. Hawk 4000 HMI Logic Module connections

Serial (not usedon standard system)

USB EtherNet 120VAC power

Figure 2-4. SM2 Modbus Module

2-4 Part No. 750-342

Hawk 4000 Section 2 — System Components

Figure 2-5. L33ER PLC Communication Ports

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

2.5.1 Steam Systems:Steam Pressure is the primary sensor input to the HAWK 4000 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 used for thermal shock protection and hot standby control on steam boilers. The standard location for the thermowell is

Sensor System Standard OptionalSteam Pressure ST YesStack Temperature ST & HW YesWater Temperature ST YesWater Level ST YesSupply Temperature HW YesOutdoor Temperature HW YesReturn Temperature HW YesSteam Flow ST YesFeedwater Flow ST YesO2 ST & HW YesMix O2 ST & HW YesComb. Air Temperature ST & HW Yes2nd stage economizer ST Yes

PORT 1

PORT 2

ETHERNET

BOTTOM OF CONTROLLER

USB

Part No. 750-342 2-5


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.

For optional 2 or 3-element feedwater control, Steam Flow and Feedwater Flow can be used in conjunction with water level.

2.5.2 Hot Water systems:Supply Temperature is the primary sensor input to the HAWK 4000 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.

2-6 Part No. 750-342


Section 3Hardware Setup

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2DIN Rail Latch and Expansion I/O Module Locking Levers . . . . . . . . . . . . . . . . . . . . 3-2Panel and Field Wiring Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3SM2 Module DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Burner Control Modbus Address and Baud Rate - CB780E . . . . . . . . . . . . . . . . . . . . 3-3Burner Control Modbus Address and Baud Rate - CB120E . . . . . . . . . . . . . . . . . . . . 3-6PLC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Modbus Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Setting The Modbus Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Power/ Communications LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Moving The Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Section 3 — Hardware Setup Hawk 4000

3.1 Control PanelThis 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 LeversBefore 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).

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

The PLC and rack 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 PLC rack (i.e. removing the power supply, PLC, 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.

Figure 3-1. DIN rail latches

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

Important!

3-2 Part No. 750-342

Hawk 4000 Section 3 — Hardware Setup

3.1.2 Panel and Field Wiring TerminationsCheck that all factory wiring connections are tight and that field wiring terminations are completed and secure.

3.1.3 SM2 Module DIP SwitchVerify 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).

3.1.4 Burner Control Modbus Address and Baud Rate - CB780EThe 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.

settings: Top L,Bottom R

DIP switch

Figure 3-3. SM2 module DIP switch setting

Part No. 750-342 3-3


Press ENTER buttons at the same time.

Press down arrow twice.

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


Press down arrow key to save changes.

Press down arrow key until MB BAUD is displayed.

3-4 Part No. 750-342



Press down arrow to select.

Using up or down arrow key select 9600.

Press ENTER keys at the same time.

Press down arrow key to save changes.


Part No. 750-342 3-5


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>.

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 PLC SwitchVerify that the PLC switch is in the RUN position.

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

The boiler will immediately stop if the switch is moved to the PROG position.

The switch must be in the PROG position and the Burner switch set to OFF before the PLC program can be copied to a blank SD card in “Logix folder” format.

The switch can be in either PROG or RUN position when copying a PLC program from a SD card containing a Logix folder. No other files should be present on the SD card. The Logix folder must be located at the root directory of the SD card (see Appendix B for program loading procedure).

SD cardslot

RUN/REM/PROGswitch

3-6 Part No. 750-342


3.2 Modbus Actuators3.2.1 MountingFasten 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 coupling may be connected with set screws and pinned in position or secured with a key.

3.2.2 Electrical ConnectionsThe actuators are intended to have one cable connection on the incoming side, (from the previous actuator or the Hawk panel) and one cable connection on the outgoing side, to the next actuator. The cable connectors and mounting plugs are keyed to ensure that the pins all line up correctly. To connect the cable, align the pins and the key and push into place. Turn the threaded collar clockwise to tighten and secure the cable. Secure the cables such that the cables are not pinched and do not interfere with the mechanical movement of the actuated devices.

In some installations, codes or other requirements may call for the actuators to be hard wired. See Figure 3-5.

It is recommended that the actuator drive shaft remain decoupled from the valve 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.

Figure 3-4. Actuator Wiring, Quick Plug

Part No. 750-342 3-7


Figure 3-5. Actuator wiring (hard wired)

3.2.3 Setting The Modbus Node AddressThe 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.

R R W

G

BL

G

W

BRN

BRN

BRN

BRN

ORG

ORG

ORG

ORG

BLK

BLK

BLK

BLK

RED

RED

RED

RED

3-8 Part No. 750-342


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

Actuator Node Address Table:

All actuators must have a UNIQUE node address.

3.2.4 Power/ Communications LEDEach 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.

Figure 3-6. Actuator, cover removed

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

Actuator AddressAir Actuator 1 1Fuel 1 Actuator 1 2Fuel 1 Actuator 2 3Air Actuator 2 4Fuel 2 Actuator 1 5Fuel 2 Actuator 2 6FGR Actuator 7Fuel 3 Actuator 1 8Fuel 3 Actuator 2 9

Rotary switch - set node address

Part No. 750-342 3-9


3.2.5 Moving The ActuatorThe actuator can be moved clockwise or counterclockwise by pressing either one of two red buttons located on the actuator. 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 and shut down the boiler.

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.

Figure 3-7. Actuator manual pushbuttons

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

Clockwise or counter-clockwise actuator shaft rotation is as seen from the viewing perspective shown below.

Counterclockwise (CCW)

Clockwise (CW)

3-10 Part No. 750-342


Section 4System Configuration

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Logging in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Configuration Screen #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Boiler Media and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Fuel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Actuator Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Configuration Screen #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Variable Frequency Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Configuration Screen #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Economizer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Feedwater Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17Feedwater Level Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Configuration Screen #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20Remote Modulation/Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20Dual Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22Hot Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Configuration Screen #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Configuration Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24Auxiliary Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Aux Analog Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25VFD Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26Email Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

SMTP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32Text/Email Contact List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

PanelView Plus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23Change the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33Installing a PV+ Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34Viewing the PV+ Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41

Section 4 — System Configuration Hawk 4000

4.1 IntroductionThe Hawk 4000 is equipped with a 7” (optional 10”) 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

4.1.1 Logging inCertain actions on the HMI require a password before allowing user input. The Hawk 4000 employs three levels of security: Operator, Service, and Factory. When a password is required, the login entry window is displayed.

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

Figure 4-1. Hawk 4000

4-2 Part No. 750-342

Hawk 4000 Section 4 — System Configuration

Press Enter after typing User Name and after typing Password. When both are entered, press <Login>.

4.2 Main MenuThe Main Menu (Figure 4-3) 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, 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>).

Figure 4-2. Alphanumeric keypad

Part No. 750-342 4-3


Figure 4-4. Main Menu (initial startup)

Figure 4-3. Main Menu (all possible screens)

4-4 Part No. 750-342


4.3 Boiler OverviewThe Boiler Overview display (Figure 4-5) 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.

Figure 4-5. Boiler Overview screens

Firetube Steam

Flextube Steam

Model 4/5 Steam

Firetube HW

Flextube HW

Model 4/5 HW

Part No. 750-342 4-5


4.4 System ConfigurationThe first step in commissioning t h e b o i l e r is to configure the control system options. On the Main Screen press <System Config >.

A warning message i s d isp layed:

Press <System Config> again; a final warning screen will appear.

Press <System Config> to continue.

Password login will be required to configure the system.

The following items are configurable when in system configuration.

Configuration Screen 1:

• Boiler Media Steam or Hot Water• Boiler Type - Firetube, Flextube or M4/M5 boiler• Safety Valve Setpoint (Steam)/Max Rated Temperature (HW)• NOx Level (PPM)• Number of Fuels (up to 3)• Fuel Control Method (Parallel Positioning or Single Point)• Fuel Type and Turndown for each fuel• Steam transmitter span• FGR (Yes/No)• 2nd fuel actuator (Yes/No) for each fuel• 2nd Air Actuator


• Flame Safeguard Selection (CB780E / CB120E)• Revert to Pilot (CB120E Only)• Revert to Pilot Signal Select (CB120E Only)• VFD Model / Min.% / Bypass / Ethernet communications• Remote Modulation/Setpoint Signal Selection• O2 Analyzer• O2 Trim• Low O2 Shutdown Option• Mix O2


• Combustion Air Temp Option Selection• Level Master Option selection (Steam Boiler)• Expanded diagnostics (Slot 7) selection • Aux Analog Inputs (Slot 8) selection• 2-Stage Economizer configuration (Steam Boiler)• Draft Control select• Feedwater level control selection and type - 1, 2, or 3-element (Steam Boiler)• Outdoor Temperature (HW)• Return Temperature (HW)

Figure 4-6. Warning

4-6 Part No. 750-342



• 2 Boiler Lead Lag / Master Panel Lead Lag select• Remote Modulation Source select (Analog Input / Communications)• Hot Standby• Remote Setpoint source select (Analog Input / Communications)• Dual Set Point• Outdoor Temp Reset (HW)


• Enter customer name, boiler ID and serial number, Alarm Input #1-2 name if enabled.

Pressing <Next> from Configuration Screen #5 will show the Configuration Summary screen. Configured values will be shown for all parameters.

If the <Confirm Options (Required)> pushbutton is visible, it must be pressed to accept the new system configuration

Note: The boiler will not start while a “System Config” screen is displayed.

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

4.5 Configuration Screen #14.5.1 Boiler Media and Type The first step in the configuration procedure is to select the boiler media and type.

Note - 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.

Part No. 750-342 4-7


Press <Boiler Media> for the following screen:

Figure 4-8. System configuration

“Firetube” is selected as the default 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 media will also bring up the <Next> button, allowing the user to advance to the next configuration screen.

Figure 4-7. System Configuration Screen #1

4-8 Part No. 750-342


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. Boiler Media selected

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 at the top right 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. The range of valid entries as well as the currently entered value are shown above the keypad. An out-of-range 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.

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).

Popup keypad Invalid entry

CURRENT VALUE

RANGE

Part No. 750-342 4-9


Maximum Rated Temperature (Hot Water)

All Types = Between 200-400 Deg F

Safety Valve Setpoint (steam)

On a steam boiler, the proper safety valve setting should correspond to the pressure setting of the steam safety valve(s) on the boiler.

A hot water boiler is configured similarly. The max rated temperature of the boiler should be entered. This number should not exceed the maximum design temperature of the boiler. Default for hot water boilers is 250º F. Contact your local Cleaver-Brooks representative if you do not know the maximum temperature rating of your boiler.

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:

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.

Safety Valve Setpoint MaxFiretube 400 psiFlextube 250 psiM4/M5 600 psi

! Warning

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

Safety Valve Setpoint psi

Steam Transmitter Span psi

15.0 or less 15.015.1 to 150.0 150.0150.1 to 300.0 300.0300.1 to 500.0 500.0500.1 to 600.0 600.0

4-10 Part No. 750-342


Note: Remote Setpoint and Dual Setpoint options are NOT available for low emission steam boilers (NOx level less than 60.0 PPM).

4.5.2 Fuel Configuration

Figure 4-10. Fuel configuration

Number of Fuels

Enter the Number of Fuels for this application.

Acceptable values are 1, 2, or 3.

Control Method

Select the type of combustion control method for this application.

Acceptable entries are Parallel Positioning or Single Point Positioning.

Fuel Type

Select the Fuel type for each fuel for this application.

When pressing the Fuel Type push button a selector is displayed:

Use the up/down arrows to select the correct fuel. Press the enter key to accept the selection. Press <Close> to return to Configuration Screen #1.

Part No. 750-342 4-11


Turndown

Enter the Turndown for each fuel for this specific application.

The turndown entry affects the boiler efficiency calculations - it has no impact on the burner's actual turndown. Turndown ratio is established during burner commissioning by a qualified burner technician.

4.5.3 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


Fuel 3 Actuator 2


Air Actuator 2

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

Figure 4-11. Actuator selection

When fuel configuration is complete, press <Next> to go to Flame Safeguard configuration (Configuration Screen #2).

4.6 Configuration Screen #2

4.6.1 Flame Safeguard

Figure 4-12. FSG configuration

4-12 Part No. 750-342


Select the type of Flame Safeguard used for the application.

The CB780E and CB120E are the two selections available on the Hawk 4000

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

Revert to Pilot

Revert to Pilot is selected if “Yes” is displayed on the <Revert to Pilot> push button.

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

If Process Variable is selected the setpoint for Revert to Pilot must be entered from the Revert to Pilot setpoint screen.

If Digital Input is selected, when discrete input I2/7 ALFCO is turned off, Revert to Pilot will be initiated.

4.6.2 Variable Frequency Drives

The Hawk 4000 supports PowerFlex 400, 700, 70, and 753 drives. Other manufacturers’ VFDs are not recommended. EtherNet communications to the VFD are available only when using a PowerFlex drive.

! Caution

Revert to Pilot modes are to be determined in the field after careful analysis of the load conditions that necessitate the use of this feature.Care should be taken to avoid unnecessary recycling and damage to the boiler equipment.

Figure 4-13. Revert to Pilot - Steam Pressure

Part No. 750-342 4-13


VFD Model

Select the appropriate VFD Model for this specific job. The available options are None, PowerFlex, and Other Mfg.

VFD Minimum Percent

This is the minimum percent output that the VFD will be commanded to run.

VFD Bypass

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

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

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

Figure 4-14. VFD configuration

VFD Ethernet

Select “Yes” if using Ethernet for VFD communications. If using Ethernet communications and <PowerFlex> is selected as the drive model, you are required to specify the VFD type - PowerFlex 400, PowerFlex 70, PowerFlex 700, or PowerFlex 753 drive.

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

4.6.3 Options

Oxygen Analyzer

The Oxygen (O2) Analyzer 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.

O2 Trim

02 trim control is an integral part of the HAWK 4000 system. This feature affords additional control over fuel-to-air 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. The Flue Gas O2 Control Screen can be accessed from the HMI Main screen.

Figure 4-15. O2 Analyzer

4-14 Part No. 750-342


To view O2 trends or to adjust the O2 Trim PID tuning, press <Tuning & Trend>.

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 toggling “O2 Shutdown” (on the System Configuration screen) between <Yes> and <No>.If enabled the Low O2 Shutdown Setpoint and Low O2 shutdown time delay can be adjusted on the Alarms and Limits screen.

Mix O2

This feature is for use with CB NTI burners in Ultra Low NOx applications. Mix O2 trim uses a probe mounted in the boiler front head to monitor O2 levels in the combustion air in order to maintain optimum FGR rate.

If Mix O2 is selected in System Configuration, a Mix O2 control screen similar to Figure 4-16 will become available, with sensor calibration, manual/auto control, and setpoint/actual value displays.

Figure 4-16. Flue Gas O2 Control Screen

Figure 4-17. O2 Tuning & Trends

Part No. 750-342 4-15



Combustion Air TemperatureThe 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.

Level MasterSelect <Yes> if using a CB Level Master for water level control (steam boilers).

Feedwater TemperatureWhen selected, displays boiler feedwater temperature on Boiler Overview screen.

Expanded DiagnosticsUsed for alarm annunciation. Digital input module (Slot 7) required.

Auxiliary Analog InputsSelect if optional analog inputs are required. Slot 8 analog input module required.

Draft ControlSelect <Yes> to make Draft Control setup and control screens accessible from the Main Menu. If using Hawk draft control refer to manual 750-221.

Surface ThermocoupleUsed on Hawk retrofits where a temperature probe is not available for shell water temperature input.

4.7.1 Economizer Configuration

If using an economizer, select <Yes> for Economizer 1 Stage or Economizer 2 Stage according to the type of economizer. Selecting Yes will display the economizer graphically on the Boiler Overview screen.

Select <Temp In> and/or <Temp Out> to show the Stage 1 water temperature in/out.

NOTE: Hawk 4000 2-stage economizer control is for single boiler applications only.

Figure 4-18. Configuration Screen #3

4-16 Part No. 750-342


4.7.2 Feedwater Level Control

The Hawk 4000 can perform one, two, or three-element feedwater control. Selecting <Yes> for Feedwater Level Control will display a button for Feedwater Control Type and a window showing the inputs necessary for the chosen control mode.

• One-element control requires a Level input at I4/1 (may be CB Level Master).• Two-element control requires Level as above and Steam Flow at Analog Input I8/3.• Three-element control requires Level and Steam Flow as above, and Feedwater Flow at Analog Input

I8/4.

One-element control - A control signal from the water level sensor is used as the process variable. This value is compared to the setpoint, and based on PID settings a control output is calculated and sent to modulate the feedwater valve.

Figure 4-19. Economizer configuration

PV

LT

SPOperatorsetpoint

CV

I4/1

O5/3

To feedwater valve

1-element level control

PIDCONTROL

Figure 4-20. 1-Element Control

Part No. 750-342 4-17


Two-element control - Similar to single element control; a control signal from the water level sensor is used as the process variable. In addition, steam flow is used as a feedforward signal to help the control output respond to load changes.

Three-element control - This is a cascade type control involving two PID loops. The first loop is a 2-element feedwater control. The output of this loop is the setpoint for the second loop. The process variable for the second loop is feedwater flow. This type of control provides better response to rapid steam load changes.

4.7.3 Feedwater Level Control Setup

If “Level Master” is selected its analog input will be scaled automatically on the Feedwater Level Setup screen and will be used for the water level input at I4/1 for Feedwater Control.

If Level Master is not selected then a separate level transmitter must be used for the water level input at I4/1 and scaled on the Feedwater Level Setup screen.

Reverse Level Input Signal - The Feedwater Valve Input Signal may be reversed unless a Level Master is being used.

Reverse Feedwater Valve Output - The Feedwater Valve Output may be reversed if required.

PID tuning parameters may be adjusted for all 3 control loops from this screen.

PV

LT

SPOperatorsetpoint

CV

I4/1

O5/3

To feedwater valve


I8/3STEAM FLOW

PIDCONTROLFF


O5/3

To feedwater valve

PV PV

LT

SPOperatorsetpoint

CV CV

I4/1


I8/3STEAM FLOW

PIDCONTROL 1

PIDCONTROL 2

SP

FW FLOW

I8/4

FF


4-18 Part No. 750-342


Figure 4-23. Feedwater Level Setup Screen

Figure 4-24. Feedwater Level Control Screen

Part No. 750-342 4-19


Feedwater Valve% of Full Travel - Used to limit the control output to the valve.

Steam Flow% required for 2/3 Element Control - Although 2 or 3 element Feedwater Level Control is selected, the Active Control will be 1 element until the Steam Flow% becomes greater than the Steam Flow% Required for 2/3 Element Control. Once the steam flow exceeds this value 2 or 3 element Feedwater Control (whichever is selected) will become active.

Steam Flow must be in units of Lb/Hr. These units are automatically configured for analog input I8/3.

Feedwater Flow may be in units of Lb/Hr, GPM, or GPH. If a unit other than Lb/Hr is selected for Feedwater Flow a calculated value in Lb/Hr will be displayed on the HMI.


4.8.1 Lead Lag

CB 2 Boiler Lead Lag

For 2 Boiler Lead Lag select Master or Slave. If the boiler controller being configured has the header transmitter connected to it, this boiler will be the “Master” - if not, it will be the “Slave” (“Master” as used here should not be confused with the CB Master Lead Lag option below).

If Master is selected, the 2 Boiler Lead Lag Setup and Control screens will now be available from the Main Menu.

CB Master Lead Lag

If the boiler will be utilized in a CB Master Panel control system, select <CB Master Lead Lag>. The boiler controller will need the proper wiring connections with the master controller to function properly. See the CB Master Panel manual (#750-375) for further information on Master Lead/Lag configuration and operation.

4.8.2 Remote Modulation/Remote Set Point

Figure 4-25. Configuration Screen #4

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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). A green indicator shows selections which may be changed; selections with red indicators may not be changed.

Remote Modulation by Analog Input

This configures the Boiler Controller to receive a remote 4-20mA signal on input I4/3 to control the firing rate of the boiler.

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 I2/14. 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 reverts to the LOCAL setting on the HMI.

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 to receive a remote 4-20mA signal on input I4/3 to vary the set point of the boiler.

Note: Remote Setpoint is not allowed for low emission s team boilers.

With Remote Setpoint selected, the analog signal can be scaled to the engineering units on the “Alarm and Limits” Screen, by setting the Remote Setpoint Scaling values (zero and span) of the 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 Remote Set Point by isolated contact input signal (120 VAC) on digital input I2/14. When that input is de-energized, the Boiler Controller will revert back to local setpoint control. If Remote Set point operation will be enabled manually, select <HMI Input>. Remote Setpoint can then be enabled, by selecting the <Remote> button on the Firing Rate Screen.

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

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

4.8.3 Dual Set PointDual 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 I2/14. Press the button to the right of “Dual Set Point Selection By” to toggle between <HMI Input> and <Digital In>.

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).

4.8.4 Hot StandbyThe 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).

! Warning

Remote 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 Remote Set Point control is allowed on your boiler. Failure to follow these precautions may result in damage to equipment, serious personal injury, or death.

! 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.

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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.

Outdoor Temperature Reset (Hot Water units only) With this option selected, a correction based on the outdoor temperature will be applied to the operating set point. An outdoor temperature transmitter is required on Analog Input I6/2for this feature. When the outdoor temperature is selected for Analog Input I6/2 outdoor temperature is displayed on the boiler overview screen.

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.


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

Figure 4-27. 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. The Customer name is limited to 30 characters, including spaces.

Auxiliary Alarm 1-2

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If the system has auxiliary alarms the text that is displayed when the auxiliary 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 7 Input 14

Auxiliary alarm 2 must be wired to Slot 7 Input 15

For example: If Auxiliary Alarm 1 is entered as Water Pressure Low and Discrete Input I7/14 is “On” the alarm displayed on the HMI for Auxiliary Alarm 1 will read “Aux 1 - Water Pressure Low”.

4.10 Configuration SummaryOnce 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.

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

The Configuration selections may be changed after the HAWK 4000 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.

Figure 4-28. System Configuration Summary

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4.11 Auxiliary Analog InputsThis optional feature provides 3-8 user defined inputs depending on the options selected. An 8 channel analog input module is required in Slot 8.

• 2nd Stage Econ uses 2 user defined inputs• Mix O2 uses 1 user defined input• 2 Element Feedwater uses 1 user defined input• 3 Element Feedwater uses 2 user defined inputs

4.11.1 Aux Analog Input ConfigurationGo to <Analog Config [1-4]> to configure the auxiliary analog inputs.

Figure 4-29. Aux Analog Inputs

Figure 4-30. Aux Analog Input Configuration

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Name - Enter any name (20 characters maximum).

Units - Enter any unit (8 characters maximum)

Input Range in EU - User defined scaling on analog input device

Enable Alarms:

Yes - For High Alarm, if input is greater than entry for 2 seconds, alarm will result

For Low Alarm, if input is less than entry for 2 seconds, alarm will result

Bad Quality Alarm – alarm enabled for 1.5 seconds

No – No Alarms Active

Flow Input - “Yes” will totalize analog input (if yes, time base for totalizer must be set).

Inputs can be monitored and trend screens accessed from <Analog Inputs [1 or 2]>:

4.12 VFD Ethernet ConfigurationIf a PowerFlex drive will be connected to the Hawk 4000, the drive must have a properly configured Ethernet communications module.Once the drive is connected to the boiler network, the Ethernet communications option needs to be selected via the HMI and the drive IP needs to be entered. With this step completed, the HMI can be used to download the Cleaver-Brooks default drive parameters and to set motor nameplate data. If using a custom IP configuration proceed as below, entering customer IP information where appropriate.

Configuring the PowerFlex drive Ethernet communications

The following procedure uses the VFD local display/keypad.

1.PowerFlex 400/70/700:Press the ESC key until the Parameters or Programming menu is displayed.

1.PowerFlex 753:Press the right arrow key until ENETR is displayed. Proceed to step 5.

2.From the Programming screen press until DSEL is selected.

Figure 4-31. Analog Inputs Screen

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3.Press

4.Press or to highlight the communication module.

a.PowerFlex 400: 22-COMM-E.

b.PowerFlex 70/700: 20-COMM-E.

c.PowerFlex 753: ENETR

5.Press

6.Individual parameters can be accessed either by pressing or until the desired parameter number is reached or by entering the parameter number via the keypad and pressing

7.Set BOOTP parameter to “0” (disabled).

a.PowerFlex 400: Parameter 02

b.PowerFlex 70/700: Parameter 03

7. PowerFlex 753: Set Parameter 05 [NetAddrSel] to ”1”

8.Reset the adapter by power cycling the drive.

a.Open the electrical disconnect.

b.Wait for capacitors to discharge (about 30-60 seconds depending on drive size).

c.Close the electrical disconnect.

9.Configure the IP address.

a.PowerFlex 400: Parameter 03 through 06

b.PowerFlex 70/700: Parameter 04 through 07

c.PowerFlex 753: Parameter 07 through 10

Default IP addresses are as follows

10.Configure the Subnet Mask.

a.PowerFlex400: Parameter 07 through 10

b.PowerFlex70/700: Parameter 08 through 11

b.PowerFlex 753: Parameter 11 through 14

Default Subnet Mask 255.255.255.0

11.Configure the Gateway Address.

a.PowerFlex400: Parameter 11 through 14

b.PowerFlex70/700: Parameter 12 through 15

b.PowerFlex 753: Parameter 15 through 18

Default Gateway 192.168.1.1

12.Configure the data rate to “0” (Autodetect).

Boiler 1 Boiler 2 Boiler 3 Boiler 4VFD 192.168.1.111 192.168.1.112 192.168.1.113 192.168.1.114

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a.PowerFlex400: Parameter 15

b.PowerFlex70/700: Parameter 16

b.PowerFlex 753: NA

13.Reset the adapter by power cycling the drive.

a.Open the electrical disconnect.

b.Wait for capacitors to discharge (about 30-60 seconds depending on drive size).

c.Close the electrical disconnect.

The communications adapter is now configured.,

Configuring the HMI for PowerFlex drive Ethernet communication

Selecting “PowerFlex” as the VFD Model will make the VFD Ethernet button appear. When <VFD Ethernet> is enabled, the VFD Type button will appear. Activate PowerFlex 400, 70, 700, or 753 based upon which drive is used.

If <Other MFG> is selected for VFD Model, Ethernet communications are not available.

Figure 1. Configuration #2 screen - select PowerFlex Ethernet communications.

Once the VFD Ethernet option has been selected and the IP address of the PowerFlex drive has been configured, press <Blower VFD Config> from the Main Screen to enter the Drive Configuration screen.

Figure 2. Initial PF Drive configuration screen.

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The IP address will initially be set to zeros. Also, if PowerFlex drives are de-selected, the IP address will be zeroed. A warning will display whenever the address is not set or the PLC cannot connect to the drive. Enter the IP address using the associated IP address octet button.

When the IP address has been entered, press the <Set VFD IP Address> button. Once Ethernet communications have been established, the motor nameplate data and <Load C-B Defaults> buttons will appear.

Figure 4. Motor nameplate information

Depending on the VFD type selected, the respective parameters for the motor nameplate data will be displayed. Enter the corresponding information to properly configure the nameplate data.

The PowerFlex 70/700/753 drives have a few more parameters requiring configuration than the PowerFlex 400. Enter the corresponding information to properly configure the nameplate data.

The drive configuration is stored in the PLC and will be downloaded once the <Load C-B Defaults> button is pressed. This process will take several seconds to complete. The <Load C-B Defaults Help> button explains this process. Upon successful completion, the VFD will have its parameters set to Cleaver-Brooks requirements.

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Figure 5. Load C-B Defaults Help screen

Once configured, the drive status can be monitored on the Blower VSD screen. The left-hand side of the screen will display the drive status word as well as indicate if a drive fault or alarm is active. If a fault exists, it can be cleared by pressing the Clear Drive Fault button or access the Drive Faults screen to view the fault and recommended corrective actions.

The right-hand side of the screen provides visualization of the drive output.

The Output Amps gage will automatically scale based on either the motor current rating or the drive rated amps.

The Output Power (in kilowatts) scale is preset for the PowerFlex 400, and scalable based upon the PowerFlex 70/700/753 rated kilowatts.

Fan Speed is displayed on a fixed scale of 0-4000 rpm and is based upon drive output frequency.

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Figure 6. PowerFlex drive data

The Drive Faults screen will display the current drive fault (if present). Also displayed is a description of the fault and recommended corrective actions. Press and hold the Last Drive Fault button to see the previous fault.

Figure 9. Current and Last drive fault information displayed on the Drive Faults screen.

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4.13 Email SetupEmail or text messages can be send directly from the PanelView Plus, provided SMTP Server Configuration has been completed.

The PV+ must be at hardware revision 6.0 and firmware revision 7.0.20.13 or greater.

4.13.1 SMTP Configuration

SMTP (Simple Mail Transfer Protocol) is a standard protocol for the exchange of electronic mail over the Internet. It will be the user’s responsibility to determine the SMTP server information for email configuration; an example configuration is shown below. A help screen is available (press <SMTP Help>). User’s IT personnel should be consulted if necessary.

4.13.2 Text/Email Contact ListThe HMI will store up to six email addresses. Each can be receive enabled (WILL SEND) or disabled (WILL NOT SEND). Enabled addresses will receive an email for every alarm activation.

Press <Email Help> for assistance in configuring this page, or consult the appropriate IT personnel.

Figure 4-32. SMTP Configuration (example)

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4.14 PanelView Plus SetupThe PanelView Plus 6.0 terminal has onboard software to perform and configure terminal operations. To access the internal PanelView settings (PanelView Configuration Mode) press <PV+ Config> on the Hawk Main Screen.

4.14.1 Change the Date and TimeSelect Terminal Settings>Time/Date/Regional Settings>Date. The current date appears in the Year, Month, and Day fields.

Press the Year, Month, and Day buttons to change the values. Press <OK> when done.

To change the time, Select Terminal Settings>Time/Date/Regional Settings>Time. values.Press the Hour, Minute, and Seconds buttons to change the values. Press <OK> when done.

To change the time zone, select Terminal Settings>Time/Date/Regional Settings>Time Zone.

Figure 4-33. Email List

Figure 4-34.

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Press the Daylight Savings button to enable or disable daylight savings for the selected time zone. Daylight Savings is set to Yes for all time zones except for Japanese, which does not support daylight savings.

Daylight savings changes are not permanently applied until you close the Time Zone screen.

Press the <Use Daylight Savings> button to select Yes or No. Click OK when done, then <OK> again to return to Terminal Settings.

4.14.2 Installing a PV+ ProgramThe following is a procedure to install a PanelView Plus program to the PV+ terminal using an SD memory card.

I. COPY PV+ RUNTIME APPLICATION TO THE PV+ TERMINAL

1.Copy the Rockwell Software folder to an appropriate memory device. There should be nothing else on the card but this folder. If you have a zip file, the file must be unzipped.

2.The file structure where the runtime file resides must be exactly as follows.

Before attempting to work with the PanelView Plus, users should read and understand the PV+ User Manual - Rockwell publication 2711P-UM006D-EN-P March 2015

Figure 4-35.

Figure 4-36.

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Rockwell Software RSViewME Runtime Filename.mer (example: 98500553_000.mer)

3.At this point if there is an Ethernet switch in the electrical control cabinet be sure that there are only 2 Ethernet cables plugged into the Ethernet switch. One cable from the PLC and one cable from the PV+.4.Power up the PV+ and insert SD card or USB device into slot provided.5.From the PV+ Configuration Mode (FactoryTalk ME Station), touch Terminal Settings [F4].

Figure 4-37.

6.From Terminal Settings, select File Management. Press the Enter arrow.

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Figure 4-38.

7.Select Copy Files. Press the Enter arrow.8.Select Copy Applications. Press the Enter arrow.9.Using the Source [F1] button, select External Storage 1 (the green bullet should move down to that selection). Use the up/down buttons to select the application you want to load and then press the Destination [F2] button. If the External Storage 1 cannot be selected, the PV+ cannot read the SD card. Try a different card or verify the file structure on the SD card is exactly as stated in Step 2 of this document.10.From the Copy Applications Destination screen, the green bullet should be on Internal Storage. If it is not press Destination [F1] until the green bullet is on Internal Storage. Press the Copy [F2] button. 11.After the file is copied you should be back in the Copy Applications screen. Press Cancel [F8]. 12.You should now be on the Copy Files screen. Press Close [F8].13.You should now be on the File Management screen. Press Close [F8].

13a. You should now be on the Terminal Settings screen. Press Close [F8].

13b. Press Load Application [F1].

14.With the correct application highlighted and the green bullet on Internal Storage, load the application from Internal Storage by pressing Load [F2].

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Figure 4-39.

15.A message appears asking “Do you want to replace the terminal's current communication configuration with the application's communication configuration?” IMPORTANT: Press Yes [F7] if this is the first time loading the application and communication has yet to be established, otherwise press NO [F8].

16.You should be back on the FactoryTalk View ME Station screen. The application Filename.mer should appear in the Current application window. Press Terminal Settings [F4].

II. DEFINE AN ETHERNET IP ADDRESS FOR THE PV+ TERMINAL17.You should now be back on the Terminal Settings screen. Select Networks and Communications. Press the Enter arrow.18.From the Networks and Communications screen select Network Connections. Press the Enter arrow.19.From the Network Connections screen select Network Adaptors. Press the Enter arrow.20.From The Network Adaptors screen, with Built-in Ethernet Controller highlighted, press IP Address [F2].

Figure 4-40.

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21.From the IP Address screen select press the Use DHCP [F4] until the green bullet is in the No position and the IP Address [F1] button is enabled.

Figure 4-41.

22.Press IP Address [F1] and enter the IP address with the pop-up keypad provided. The Standard IP addresses for the PV+ are as follows: NOTE: If the unit must be on a custom network, Ethernet parameters must be obtained from the user’s IT department.192.168.1.121 for Boiler 1192.168.1.122 for Boiler 2192.168.1.123 for Boiler 3192.168.1.124 for Boiler 4192.168.1.125 for Boiler 5192.168.1.126 for Boiler 6192.168.1.127 for Boiler 7192.168.1.128 for Boiler 8

Press the Enter key.

23.Press Subnet Mask [F2] and enter 255.255.255.0 Press the Enter key. 24.Press Gateway [F3] and enter 192.168.1.1 Press the Enter key.25.After entering IP Address, Subnet, and Gateway, press the Ok [F7] key.26.A message will come up. From the Adapters screen press Ok [F7].27.From Network Adapters screen press Close [F8].28.From the Network Connections screen press Close [F8].

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Figure 4-42.

III. SETTING RSLINX ENTERPRISE EHTERNET COMMUNICATIONS

29.You should be on the Networks and Communications screen.30.From the Networks and Communications screen select RSLinx Enterprise Communications. Press the Enter arrow.31.If the Ethernet IP address for the PLC in this RSLinx Network needs to be revised arrow to highlight the Ethernet IP address for the PLC. Example: PLC, 192.168.1.101 (should be highlighted)Press Edit Device [F1].NOTE: IT IS VERY IMPORTANT THAT THE ETHERNET IP ADDRESS SET IN THE PLC MATCHES THE PLC IP ADDRESS ENTERED ON THIS SCREEN.

32.Press Device Address [F1].33.Press the Backspace key and enter in the correct PLC IP address for this system192.168.1.101 for Boiler 1192.168.1.102 for Boiler 2192.168.1.103 for Boiler 3192.168.1.104 for Boiler 4192.168.1.105 for Boiler 5192.168.1.106 for Boiler 6192.168.1.107 for Boiler 7192.168.1.108 for Boiler 8

34.Press Enter

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35.Press OK [F7]36.From the RSLinx Enterprise Configuration. 37.If the Ethernet IP address for the PV+ in this RSLinx Network needs to be revised arrow to highlight the Ethernet IP address for the PV+. Example: PV Plus, 192.168.1.121 (should be highlighted) Press Edit Device [F1].38.Press Device Address [F1].39.Press the Backspace key and enter in the correct IP address for this PV+192.168.1.121 for Boiler 1192.168.1.122 for Boiler 2192.168.1.123 for Boiler 3192.168.1.124 for Boiler 4192.168.1.125 for Boiler 5192.168.1.126 for Boiler 6192.168.1.127 for Boiler 7192.168.1.128 for Boiler 8

40.Press OK [F7]41.Press Close [F8]42.From Networks and Communications Press Close [F8]43.From Terminal Settings Menu, Select Startup Options.Press the Enter arrow.44.Select FactoryTalk View ME Station Startup. Press the Enter arrow.45.Using the On Startup [F1] button, put the green bullet to Run Current Application. 46.Press Run Options [F3]47.Press Replace RSLinx Enterprise Communication [F1] until the green dot is on NO

a. Press Delete Log Files [F2] on every power cycle until green dot is on NO

48.From Run Options Press OK [F7]49.Press OK [F7]50.You should now be on the Terminal Settings screen. Press Close [F8].51.Press Reset [F7]52.Do you want to reset the terminal? ….Yes [F7]. This takes a moment!53.Terminal should reboot and run the application54.Once application is running and communicating properly remove the SD card from the PanelView Plus terminal. When all devices on the network are configured with a unique IP address the interconnecting Ethernet cables between the configured devices may be plugged into the Ethernet switch and communications verified.55.END OF PROCEDURE

4.14.3 Viewing the PV+ FirmwareTo check the PV+ firmware version, from the Configuration Mode main screen, go to Terminal Settings>System>Information>About FactoryTalk View ME Station.

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4.15 Remote MonitoringThe PanelView Plus 6 HMI provides Web Server functionality, allowing for easy access to plant floor HMI applications. There is no need to install any additional Rockwell software on the browser computer.

Once you have an Ethernet connection between a computer and the PanelView Plus 6 terminal, simply choose a web browser such as Internet Explorer or Google Chrome and type in the IP address of the HMI running the application you wish to view. Note there can only be one connection to an HMI at a time.

Figure 4-43. PV+Firmware

Figure 4-44. Remote Monitoring

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Section 5Commissioning

Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Setting Combustion - Parallel Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Store Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Store Lightoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7Curve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9No VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Combustion Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10Tuning and Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12Alarms and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Alarms and Limits Screen 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15Alarms and Limits Screen 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16Operating Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16Outdoor Temperature Reset (Hot Water only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16Hot Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

Revert to Pilot (CB 120E only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18Mix O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19VFD Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-5-19Two Boiler Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Lead Lag Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22Lead Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

Thermal Shock Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24Two-Stage Economizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25

Section 5 — Commissioning Hawk 4000

5.1 Commissioning the ActuatorsWhen 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.

Figure 5-2. Actuator commissioning

NOTE: Any combustion curves previously stored for the current fuel will be erased once the actuator commissioning process has been enabled. Press <Enable Air Actuator Commissioning> 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).

Actuator Commissioning Screen Warning

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Hawk 4000 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 requires the closed position to be greater than the open position. CW rotation requires the open position to 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.

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Figure 5-5. Verify actuator calibration

<Test Close> and <Test Open> will move the actuator to the stored close/open position with a single press of the button.

5.2 Setting Combustion - Parallel PositioningWhen 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.

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.

Invalid Data Save Data

Main Screen

Warning

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5.2.1 Store PurgeThe 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 5-8. Purge/Lightoff help

For a valid Purge position the air actuator(s) must be greater than 80% open. The VFD if present must be at greater than 80% output. To set purge positions, use the <Dec> and <Inc> buttons to move the actuator/VFD to the desired position.

Figure 5-7. 2nd Warning

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Figure 5-9. Combustion Setup

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 must be set above 80%.

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5.2.2 Store LightoffWhen 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.

Figure 5-12. Store Lightoff

Figure 5-11. Combustion Setup - Purge value stored

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5.2.3 Curve SetupA help screen is available to guide the user through the steps of setting the combustion curve:

Figure 5-14. 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

Figure 5-13. Combustion Setup - Lightoff stored

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will sequence through pilot trial and main flame and the burner will ignite. The actuators can now be positioned for the first point.

• 10 points minimum must be stored for a valid curve (20 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 (10 valid points are stored) the <Setup Complete> button will appear; pressing this will go to the Combustion Control screen.

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

Figure 5-15. Combustion curve complete

5.3 Setting Combustion - Single Point Positioning

5.3.1 VFD or O2 TrimIf VFD or O2 Trim is selected, combustion setup is identical to parallel positioning, with the exception that only the air actuator will be active. 10 points minimum are required for the combustion curve, with 20 points maximum.

5.3.2 No VFD or O2 TrimThe 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.

Single point positioning uses a Modbus actuator at Node 1.

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5.4 Combustion Control ScreenThe Combustion Control screen shows setpoint and feedback signals for all configured 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. Use the Control Output <Increase> and <Decrease> buttons to ‘walk’ the actuators through the combustion curve. A help screen is available by pressing <Manipulate Actuator Help>. While manipulating the actuators, the output is not rate limited.

PID tuning for combustion control can also be accessed on the Combustion Control screen.

5.5 Firing Rate ScreenFrom 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.

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

While in Auto the boiler can be forced to low fire by an isolated 120VAC contact signal on digital input I7/2. The boiler will remain at low fire until this signal is removed.

Figure 5-16. Combustion Control screen

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5.5.1 Remote Setpoint/Remote ModulationIf Remote Setpoint or Remote Modulation is configured (requires the appropriate settings on Configuration Screen #4; see Section 4.8), the appropriate display and controls will appear on the Firing Rate screen.

Figure 5-17. Remote Modulation / Remote Setpoint

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.

A help screens is available for Remote Modulation / Remote Setpoint functions.

Remote modulation by digital input is configured. Digital input is on and Remote Mod selected.

Remote modulation by digi-tal input. Digital input is off; firing rate reverts to local control

Remote mod. by Comms

Remote setpoint by Digital Input. Remote setpoint by Comms. Remote setpoint by HMI.

Remote mod. by HMI

Remote setpoint by digital input. Digital input is off; setpoint reverts to local con-trol

Figure 5-18. Remote bad signal

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5.5.2 Dual SetpointIf Dual Setpoint is configured (requires the appropriate settings on Configuration Screen #4; see Section 4.8), the appropriate display and controls will appear on the Firing Rate screen. Dual setpoint is not available if remote modulation or remote setpoint is selected.

5.6 Tuning and TrendsFor system variables subject to PID control, a Tuning & Trend screen is accessible from the appropriate screen, as summarized below:

Screen Trended variable (press <Tuning & Trend> to view)Firing Rate Steam Pressure (Water Temperature)Flue Gas O2 Control Stack O2%Mix O2 Trim Mix O2%Feedwater Level Control Feedwater LevelTwo Boiler Lead Lag Control Header Pressure (Temperature)

Figure 5-19. Rem Mod/Rem SP Help

Dual setpoint by digital input. Digital input is off. Dual setpoint by HMI. Set-

point 1 is selected.Dual setpoint by HMI. Setpoint 2 is selected.

Dual setpoint by digital input. Digital input is on.

Figure 5-20. Dual Setpoint

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Press <PGain>, <IGain>, or <DGain> to log in and adjust the tuning. Use the left and right arrows to step back and forth through the x-axis (time) on the trend display.

Depending on system configuration, trending and totalization may also be available for specific analog inputs, accessible from the appropriate Analog Input screen.

For flow inputs, the Hawk 4000 will keep totals and will display two values below the bar graph - the current total (the first number) and the total at last reset. The units, input range, and totalizer time base are set on the respective Analog Input Configuration screen.

Figure 5-21. Tuning & Trend Screen (steam pressure)

Figure 5-22. Analog Inputs screen

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5.7 Alarms and Limits

Alarms with configurable parameters and firing rate/setpoint limits can be edited from these screens. The second Alarms and Limits screen is only available if the O2 analyzer, Mix O2, or FGR options have been configured.Configurable items include the following:

Figure 5-23. Analog Input Configuration

Figure 5-24. Alarms and Limits screen 1

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5.7.1 Alarms and Limits Screen 1High Stack Temperature Alarm and Shutdown points.

Firing Rate Limit - This value can be used to limit the maximum control output from the HAWK 4000. A value of zero will not allow the boiler to go above low fire.

Set Point Limiting - The minimum and maximum allowable setpoint values can be set here. The high and low limit points affect the Set Point and the On and Off points on the setpoint screen.

Remote Set Point Scaling - The HAWK 4000 allows a remote 4-20 mA input signal to vary the setpoint. The remote setpoint scaling enables the operator to zero and span the signal. The zero value will correspond to a remote signal of 4 mA. The span value will correspond to a remote signal of 20 mA. Remote setpoint may be enabled by a remote digital input signal or from the HMI Firing Rate screen.

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

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%

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).

Extended Pre-Purge Time - Extends pre-purge by up to 180 seconds.

Release from Lightoff Delay Time - delays the transition from lightoff to low fire by up to 180 seconds. Used for combustion stabilization.

External Device Timer - allows the Start External Device (FAD) Output to remain energized for a period of time (3-60 minutes) after a boiler shutdown.

5.7.2 Alarms and Limits Screen 2Low O2 - Select Low O2 Alarm, Shutdown, and Alarm Delay points. Low O2 Alarm only available with selection of an O2 analyzer. Low O2 shutdown only available if selected in system configuration menu.

Maximum O2 Trim Correction is the value (plus or minus) that the VFD or Air Actuator can correct (+/- 10% maximum).

Stack Low Temp. Hold - This feature is only available with FGR. Selectable to hold FGR only or FGR and firing rate (FGR & Firing Rate must be selected for 20 ppm or less systems).

“FGR Posn w/ Low Stk Temp” must be set for every combustion curve (6 maximum) and must be lower than the FGR low fire point.

If Stack Low Temp. Hold and FGR Only are 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.

If Stack Low Temp. Hold and Firing Rate are enabled and the stack temperature is below the “Stack Low Temp Hold” Set Point, the boiler is held at low fire while the FGR actuator is forced to the “FGR Posn w/Low Stk Temp” position. When the stack temperature rises above the set point for the “Delay Seconds” period, FGR will release and go to the firing rate commanded position (Low Fire). The “FGR Stabilize Delay” will allow time for the FGR to reach the Low Fire Point. When this timer expires, the boiler will be allowed to release to modulate.

Mix O2 Trim Correction is the allowable amount (as a percentage plus or minus) of FGR actuator correction (+/- 25% maximum).

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5.8 Setpoints

<Set Points> allows adjustment of Setpoint 1 (and Setpoint 2 if Dual Setpoint is configured).

5.8.1 Operating Setpoint

Figure 5-26. 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.

Figure 5-25. Alarms and Limits screen 2

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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.

5.8.2 Outdoor Temperature Reset (Hot Water only)If Outdoor Reset was selected during system configuration, the desired setpoints should be entered here.

5.8.3 Hot Standby When active, Hot Standby will cycle the boiler on if the shell water temperature (steam) or supply water temperature (hot water) 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. I2/7 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).

Figure 5-27. Outdoor reset curve

5.9 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 O3/4 or O3/7 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

-60 -40 -20 0 20 40 60 80175

180

185

190

195

200

205

Setpoint

OutdoorTemperature

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 FSet Point Range High = 200 deg FOutdoor Temp Range High = 60 deg FSet Point Range Low = 180 deg F

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proof of pilot the main gas valve de-energizes and the boiler remains on pilot. When demand returns or digital input I2/7 is ON the main gas valve is energized.

When RTP is on a “Rev to Pilot” indicator will appear on the Boiler 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]

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

Figure 5-28. 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 I2/7 ALFCO is OFF.

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

Figure 5-29. O2 Trim

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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, if one week has elapsed since the last calibration, or if initiated manually from the HMI. If using the Yokogawa analyzer, the PLC will expect a “Sensor OK” input from the analyzer at input I2/2.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 <Tuning & Trend>. Defaults are P=3, I=5, and D=0.

5.11 Mix O2The Mix O2 feature is designed to improve combustion control for Ultra Low NOx (<9 ppm) systems. Requires an 8 channel analog input module in Slot 8. If Mix O2 is selected during configuration, Input I8/2 will be automatically configured with C-B default settings.

Using an O2 probe mounted in the boiler head, the FGR valve is modulated (more FGR for lower Mix O2 levels and less FGR for higher Mix O2) to maintain optimum O2 levels throughout the firing range. A Mix O2 control screen provides features similar to standard O2 Trim control:

The <Mix O2 Trim Max Trim Correction%> is the maximum trim value allowed, expressed as a percentage of the FGR valve position. This value should be set small enough to prevent large excursions of the FGR valve, and large enough to provide sufficient valve travel to achieve setpoint.

Mix O2 sensor calibration is activated on power up, if one week has elapsed since the last calibration, or if initiated manually from the HMI.

5.12 VFD DataIf a VFD is present, <Blower VFD Data> will display a screen showing drive output and feedback, Low/High/Lightoff settings, and current running frequency.

Figure 5-30. Mix O2 Trim

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5.13 PLC Ethernet ConfigurationMultiple boilers on the same Ethernet network require unique IP addresses. To change a boiler’s configuration, press the desired field in the “Set New PLC 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. When finished, go to <Configure PLC Ethernet > and when prompted with “Set PLC Ethernet Port Configuration?” press <Yes>.

In order to configure the Ethernet port, the PLC switch must be in REM and the RUN LED must be GREEN.

Figure 5-32. Ethernet Configuration

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 Section 4 of this manual.

5.14 Two Boiler Lead LagThe Two Boiler Lead Lag option allows one boiler controller to manage the start/stop and firing rate functions of two boilers based on the load demand. The demand source is a header pressure (temperature) input at I4/3.

Figure 5-31. VFD Data

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If 2 Boiler Lead Lag Master is enabled in the Configuration section, two additional screens (for Lead Lag Setup and Lead Lag Control) will be available.

5.14.1 Lead Lag Setup

Select ModulationSelect Lead Lag (steam boilers only) or Unison modulation.

Figure 5-33. Typical Two Boiler Lead/Lag system

Figure 5-34. 2 Boiler Lead Lag Setup

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Select Lead LagSelect Master boiler as Lead and Slave boiler as Lag, or Master as Lag and Slave as Lead.

Lag Boiler settingsStart PointControl output percentage of the Lead boiler at which the “Start delay” timer is activated. Valid values are from “Stop Point” to 100%.

Start DelayThis time delay is activated when Lead boiler control output is greater than “Start Point” setting. After the time delay has expired the Lag boiler is commanded to start. Valid values are from 0 to 600 seconds.

Stop PointControl output percentage of the Lead boiler at which the “Stop Delay” timer is activated. Valid values are from 0 to “Start Point”.

Stop DelayThis time delay relay is activated when the Lead's boiler control output is less then “Stop Point” setting. After the time delay has expired, the Lag boiler is commanded to stop. Valid values are from 0 to 600 seconds.

Shutdown DelayThis is the length of time that the Lag boiler is allowed to run after the “Stop Delay” has expired. Valid values are from 0 to 600 seconds.

Modulation StartControl output to the Lead boiler at which the Lag boiler starts modulation. This parameter is only applicable to Lead/Lag modulation. Valid values are from 0 to 100%.

Header Steam Pressure (Water Temp.) settingsSet the Lead Lag Set Point, On Differential, and Off Differential.

Remote Set Point EnableSelect if using a remote set point signal at I2/14.

SequencingIf enabled, will automatically rotate the Lead and Lag boilers after Number of Days.

5.14.2 Lead Lag Control

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The Lead Lag control screen has Auto/Manual controls and graphic displays showing operational data for each boiler and for the Lead Lag System.

Note: In order for either boiler to be part of the lead lag sequence, <Remote> must be selected under “Control Mode” on the boiler’s firing rate screen.

Lead Lag Modulation - The lag boiler starts when the lead boiler’s firing rate signal reaches the Start Point (and the Start Delay has expired). The lag boiler starts modulating after the lead boiler reaches the configured Modulation Start point. The lag boiler is commanded to stop when the lead boiler’s firing rate signal reaches the Stop Point (and the Stop Delay has expired).

In the event of a header sensor failure, master and slave boilers will revert to local firing rate control.

Unison Modulation - Firing rates for both boilers are equal.

5.15 Thermal Shock RoutineSteam 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 a function generator. 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.

Figure 5-35. Lead Lag Control

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Hot Water Boilers

Thermal shock protection is activated when actual water temperature is below minimum temperature (150F for firetube boilers, 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.

5.16 Two-Stage EconomizerIf the system has been configured with a 2-stage economizer (see Section 4), additional screens will be available for economizer setup and control.

Setpoint is the economizer 2nd stage water out temperature that the PID loop will try to achieve by modulating the condensate return and/or makeup bypass valves.

If the economizer 2nd stage water out temperature is below the Output Forced to Minimum value, the control output will be set to Control Output Minimum%. Once temperature is above the Forced to Minimum temperature, the condensate return and/or makeup bypass valves will begin to modulate.

Figure 5-36. 2-Stage Economizer Setup

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Output Split Range is only applicable if BOTH the condensate return and makeup bypass valves are enabled. This is the value that determines how the control output is split between the two valves. At 0% the condensate return valve will be disabled and only the makeup bypass valve will modulate. At 100% the makeup bypass valve will be disabled and only the condensate return valve will modulate.

Output Force on PV Failure is the value that the control output is set to when the 2nd stage water out temperature analog signal fails.

Manual/Auto controls and graphic/numeric displays for monitoring economizer operation are on the economizer control screen:

5.16.1 2-Stage Economizer Analog InputsSelecting a 2-stage economizer during the configuration process will automatically configure the appropriate analog inputs.

The default 4-20mA range values are suitable for standard C-B transmitters; these values may be changed by the user.

Figure 5-37. 2-Stage Economizer Control

Figure 5-38. Two Stage Economizer Analog Input Screen

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.

5-26 Part No. 750-342


Section 6Diagnostics and Troubleshooting

System Monitoring and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Burner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2System Information/PLC Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Modbus diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4PLC Output Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5PLC Hardware Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5PLC I/O Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Combustion Curve Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7PLC Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Fault List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Section 6 — Diagnostics and Troubleshooting Hawk 4000

6.1 System Monitoring and Diagnostics6.1.1 Boiler OverviewThe Hawk 4000 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 (steam firetube)

6.1.2 Burner ControlThe Burner Control screen gives details on the installed Flame Safeguard (CB780E or CB120E).

Figure 6-2. Burner Control screen

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

CB780E CB120E

6-2 Part No. 750-342

Hawk 4000 Section 6 — Diagnostics and Troubleshooting

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 4000 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 / PLC InfoPress <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.

The screen duplicates the L33ER Status LEDs and in addition shows the current PLC firmware revision, serial number, and PLC switch position.

Figure 6-3. System Information

Part No. 750-342 6-3


6.1.4 Modbus Diagnostics

This screen logs Modbus communication errors, actuator errors, and actuator manual pushbutton faults.

In the event of a Modbus communication fault, the screen will show the FSG status at the time of the fault (up to 10 faults).

In the event of an actuator fault, the screen will indicate which actuator faulted and will display the actuator fault code. Refer to Table 6-1 for fault descriptions and possible remedies.

<Reset All Counters> will set all counters to zero and record the time/date that the reset occurred.

Table 6-1. Actuator Error Codes

Error Code # Description Possible Remedies0 No error, actuator is running normally -1 - 7 Internal CPU self check error detected. A false positive

should be a rare occurrence.Re-write the commanded position. Log when error occurred to determine frequency of error.

8 Actuator shaft is not moving as expected. Most likely, the shaft is jammed or the actuator is undersized for the application. Check linkage for binding or lubrication problems. Less likely, the supply voltage is too low or the motor may be extremely hot.

9 - 10 The actuator’s voltage regulator self checking detected an error. A false positive should be a rare occurrence.

Re-write the commanded position. Log when error occurred to determine frequency of error.

11 The supply voltage at actuator is less than 21.6V. Power cable is too long or gauge of wire is too small. Power supply may also not be able to handle the load. Measure power supply and/or monitor power supply voltage at actuator to determine where the problem lies.

12 The supply voltage at actuator is greater than 33V. Measure the power supply voltage to ensure that voltage is not set too high. Inductive or capacitive coupling may cause spikes on supply line. Separate actuator power sup-ply lines from other high power lines.

13 - 63 Not implemented; these error codes are reserved for future use.

Figure 6-4. Modbus Diagnostics Screen

6-4 Part No. 750-342


6.1.5 PLC Output DiagnosticsPress <PLC Output 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.

6.1.6 PLC Hardware OverviewThe PLC Hardware Overview screen shows a graphic representation of the PLC rack and gives the status of each device. The devices shown on this screen must match exactly the actual devices in your PLC rack.

Figure 6-5. PLC Output Diagnostics (example: NRL relay)

Figure 6-6. PLC Hardware Overview

Part No. 750-342 6-5


6.1.7 PLC I/O StatusThe PLC I/O Status screen shows the status of all PLC inputs and outputs. Digital I/O points indicate On or Off; analog I/O indicate Raw (analog signal in mA or Volts) and Value (corresponding value in engineering units).

6.1.8 Combustion Curve DataThis screen shows the combustion curve for the selected fuel.

Figure 6-7. PLC I/O Status

Figure 6-8. Combustion Curve Data

6-6 Part No. 750-342


6.2 AlarmsIf an alarm is active the alarm bell will be visible on all screens:

The bell signals the following conditions depending on its appearance:

Press the alarm bell or <Alarms> from the Main Screen to access the Alarm screen.

This screen can be toggled between <Active Alarms> and <Alarm History>. The Alarm History will store up to 200 alarms. The history can be cleared (password required) by pressing <Clear Alarm History>.

<Alarm Silence> will turn the alarm bell off until another alarm becomes active.

Yellow flashing Warning - alarm not silenced

Yellow solid Warning - alarm silenced

Red flashing Fault - alarm not silenced

Red solid Fault - alarm silenced

Figure 6-9. Alarm Screen

Part No. 750-342 6-7


6.3 PLC Status The L33ER has a bank of multi-state LEDs to indicate the controller’s operating status and communication activities. See tables below.

Table 6-2. PLC Status LEDs

Indicator Status DescriptionRUN 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

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 6-3. PLC Communication LEDs

Indicator Status Description

NS (Ethernet Net-work Status0

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.

6-8 Part No. 750-342


LINK 1/LINK 2(Ethernet Link Sta-tus)

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.

SD (SD Card activ-ity status)

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.

Table 6-3. PLC Communication LEDs (Continued)

Part No. 750-342 6-9


6.4 Fault ListTable 6-4. Hawk 4000 Fault List

Fault Text System Failure Condition Recommended Troubleshooting

Burner Control Alarm Alarm from flame safeguard alarm terminal.

Power present to PLC input I:2/12

See flame safeguard manual.

Burner Control Modbus Comm Error

Modbus communication to the flame safeguard failed.

Communication message error. Check for proper baud rate setting on the flame safeguard. Must be 9600 for CB780E and 4800 for CB120E.Check dip switches settings on PLC SM2 Modbus module.Check cable and connectors.CB780E uses Modbus channel 1 while CB120E uses Modbus channel 3 on the SM2 Module.

Water Level Low Low water level shutdown Power present at PLC input I:2/13.

Correct per boiler operating or level control manual.

Water Level High (Steam Boiler)

High water level warning Power present at PLC input I:7/12.

Check water level

Aux Low Water Cutoff Auxiliary Low water Cut Off Alarm

PLC Input I:7/4 is energized. Correct per boiler operating or level control manual.

Boiler Operating Limits Open Boiler operating limits are open.

With load demand present and burner switch “On” (I:2/15), operating limits (I:2/5) are not complete for 15 seconds.

Refer to the wiring diagram and check for open limits. If expanded diagnostic item is purchased, there will be an indication for each specific limit.

Boiler High Limit Alarm Boiler High Operating limits is open

PLC Input I:7/3 is energized. Refer to the wiring diagram and check for open limits.

External Interlock Alarm External device open. No power to the PLC input I:2/6.

Check external limits.If external limits are not used, put a wire jumper between 120 VAC and I:2/6.

Steam Pressure Low (Steam Boiler)

Steam pressure below low pressure alarm set point.

1. Check alarm settings.2. Set low pressure alarm set point to 0 to disable alarm.

Steam Pressure Sensor Failure (Steam Boiler)

Pressure Sensor failure Analog input I:4/0 is outside of range.Range> 3.3 maRange< 20.5ma

Check analog input wiring.Check jumper between V/I- and Analog Com

Water Temperature Sensor Failure (Hot Water Boiler)

Temperature Sensor failure Analog input I:4/0 is outside of range.Range> 3.3 maRange< 20.5ma

Check analog input wiring.Check jumper between V/I- and Analog Com

Combustion Air Pressure Low Low combustion air pressure PLC Input I:7/11 is energized. Check combustion air fan. Verify VFD Parameters

Combustion Air Pressure High High combustion air pressure PLC Input I:7/1 is energized. Check combustion air fan. Verify VFD Parameters

Water Flow Low (Hot Water Boiler)

Water Flow Low warning Power present at PLC input I:7/12.

Check water flow or flow switch

Water Temp Low (Hot Water Boiler)

Water Temp below low Temp alarm set point.

1. Check alarm settings.2. Set low Temp alarm set point to 0 to disable alarm.

Non-Recycle Limit Relay Failed PLC logic is not calling for non-recycle limit relay output (O:3/2), but pilot (I:2/8) or main fuel (I:2/9) inputs are “On”

Check wiring.

6-10 Part No. 750-342


Recycle Limit Relay Failed PLC logic is not calling for recycle limit relay output (O:3/0), but pilot (I:2/8) or main fuel (I:2/9) inputs are “On”.

Check wiring.

Water Level Signal Failure (Steam Boiler)

Water Level Sensor failure With water Level option selected, Analog input I:4/1 is outside of range.Range> 3.3 maRange< 20.5ma

Check analog input wiring. Measure analog input.View analog input Raw value on the HMI PLC I/O status screen.

Remote Modulation Signal Failure

Remote Mod Signal Failed With remote mod by analog, CB Master LLag, or 2 Boiler LLag Slave option selected, Analog input I:4/3 is outside of range.Range> 3.3 maRange< 20.5ma

Check analog input wiring.View analog input Raw value on the HMI PLC I/O status screen.Measure analog input.Verify System Configuration settings on HMI

Remote Set Point Signal Failure Remote Set point Signal Failed With remote set point by analog option selected, Analog input I:4/3 is outside of range.Range> 3.3 maRange< 20.5ma

Check analog input wiring.View analog input Raw value on the HMI PLC I/O status screen. Measure analog input.Verify System Configuration settings on HMI

Header Sensor Failure Header Sensor Signal Failed With 2 Boiler Lead Lag Master option selected, Analog input I:4/3 is outside of range.Range> 3.3 maRange< 20.5ma

Check analog input wiring. Measure analog input.View analog input Raw value on the HMI PLC I/O status screen.Verify System Configuration settings on HMI

Low Oxygen in Flue Gas Low Oxygen level in flue gas O2 level below alarm set point or below 0.5%

Check combustion.From system config screen check if correct O2 analyzer is selected.Check analyzer wiring.Verify O2 Calibration voltage if CB analyzer is selected

Low Oxygen in Flue Gas Shutdown

Low Low Oxygen level in flue gas

O2 level below Shutdown set point.

Check combustion.From system config screen check if correct O2 analyzer is selected.Check analyzer wiring.Verify O2 Calibration voltage if CB analyzer is selected

Stack O2 Sensor Calibration Failed

O2 analyzer calibration failed (Only applicable to CB O2 analyzer)

O2 signal (input I:4/2) must be between 4 and 6.5 VDC during calibration

Check wiring.Repeat calibration.

Fuel 1, Fuel 2, Fuel 3 Gas Pressure/Oil Temperature Low

Low fuel gas pressure/oil temperature

PLC Input I:7/5 is energized Check gas pressure regulator. Verify Oil Temperature for specific Fuel Selected

Table 6-4. Hawk 4000 Fault List (Continued)


Part No. 750-342 6-11


Fuel 1, Fuel 2, Fuel 3 Pressure/Oil Temperature High

High fuel gas pressure/oil temperature

PLC Input I:7/6 is energized Check gas pressure regulator. Verify Oil Temperature for specific fuel selected

No Fuel Selected Fuel is not selected With burner switch “On” (PLC Input I:2/15 energized), PLC inputs I:2/10, I:2/11, or Input I:7.15 are de-energized, or 2 are energized at the same time.

Check wiring. Depending on the Number of Fuels selected, either none of the Fuel Selected PLC inputs are on, or more than one Fuel Selected PLC input is on.

Fuel 2 Pressure Low Low fuel oil pressure PLC Input I:7/7 is energized

Check oil pressure. Fuel 2 is selected

Fuel 2 Pressure High High fuel oil pressure PLC Input I:7/8 is energized Check oil pressure. Fuel 2 is selected

Oil Drawer Switch Not Made Fuel oil gun is not in position PLC Input I:7/9 is energized Check oil gun position.

Atomizing Air Pressure Low Low atomizing air pressure PLC Input I:7/10 is energized Check atomizing air compressor

Stack Temperature High Alarm High flue gas temperature at the boiler outlet.

Flue gas temperature I:6/0 is above high temperature alarm setting.

Check for proper alarm setting.Deposits on the pressure vessel surface.Faulty temperature sensor.

Stack Temperature High Shutdown

High flue gas temperature at the boiler outlet.

Flue gas temperature I:6/0 is above high temperature shutdown setting

Check for proper shutdown alarm setting.Deposits on the pressure vessel surface.Faulty temperature sensor.

Stack Damper High Pressure Switch Shutdown

High flue gas pressure at the boiler outlet.

PLC Input I:7/13 is energized Check Draft Control Setup and Operation.

Aux 1 – “User Defined Alarm” PLC Input I:7/14 is energized Job Specific User defined alarm.Defined on system config screen

Aux 2 – “User Defined Alarm” PLC Input I:7/15 is energized Job Specific User defined alarm.Defined on system config screen

Air/xxx Actuator Position Deviation

Combustion air actuator failed to go to position

Difference between commanded and actual position is not within acceptable limits.

Check air damper for binding.Check alignment.Check wiring connections.Replace actuator.

Air/xxx Actuator Feedback Low Air actuator position feedback is low

Actuator feedback signal is lower than -2.0%

Check air damper for binding.Check alignment.Check wiring connections.Re-commission actuator (Fuel curve will be lost).Replace actuator

Air/xxx Actuator Feedback High Air actuator position feedback is High

Actuator feedback signal is greater than 102.0%

Check air damper for binding.Check alignment.Check wiring connections.Re-commission actuator (Fuel curve will be lost).Replace actuator.



6-12 Part No. 750-342


Air/xxx Actuator Modbus Comm Error

Communication failure Check Modbus cable to the actuators.Check connections on the actuator.Check Node address of the actuator.

Air/xxx Actuator Manual PB Pressed

Manual PB on actuator pressed while fuel valve is open.

Don’t press manual pb while fuel valve is on.Check for stuck manual button on actuator.

Air/xxx Actuator Fault [X] Actuator Hardware Fault Modbus comms reports a fault on the actuator.

Verify 24VDC on actuator.Cycle Power on Control/Actuator.

NOTE: ALL ACTUATORS WILL ANNUNCIATE THE ABOVE 6 FAULTS AND ARE ALL TROUBLESHOT IN THE SAME METHOD – XXX = ActuatorDrive Fault Blower Motor VFD alarm or

fault.VFD option is selected and no power to PLC input I2/3

Check VFD for fault and alarms (see VFD manual for corrective actions)Check wiring to input 2 on slot 3. Check VFD parameters.Check Analog Signal wiring 4-20ma control and feedback.Verify VFD digital outputs relay status

PLC I/O Module Fault [module slot #]

PLC Module faulted. PLC registers. With power “off’ check connection between modules. Replace defective module.Fault will indicate the slot of the failed module.

Remote Communications Failure

BMS Heartbeat has timed out. The BMS Heartbeat must change states within 30 seconds or an Error is generated.

Verify Ethernet cabling.Verify Ethernet communications to BMS.Verify BMS heartbeat.

Stack Temperature Sensor Failure

Sensor analog signal is either too low or too high.

Analog input I:6.0 is outside of range.Range> 3.3 maRange< 20.5ma

1. Check sensor.2. Check wiring.3. Measure analog signal 4-20ma is valid.4. View analog input Raw value on the HMI PLC I/O status screen.

Water Shell Temperature Sensor Failure (Steam Boiler)




Master PIDe Instruction Fault PIDe instruction fault. Call Cleaver-Brooks, Inc. Technical Services

Outdoor Temperature Sensor Failure (Hot Water Boiler)






Part No. 750-342 6-13


Return Temperature Sensor Failure (hot water boilers)




Combustion Air Temperature Sensor Failure



1. Check sensor.2. Check wiring.3. Measure analog signal 4-20 mA is valid.4. View analog input Raw value on the HMI PLC I/O status screen.

O2 Sensor Failure Only applicable to Yokogawa analyzer

input I:2/2 must be On 1. Check sensor.2. Check wiring.3. Check analyzer configuration.4. Check if jumper is present from terminal 11 to 4 on analyzer.

Air Actuator Not At Purge Air actuator did not reach purge position.

Check air actuator for binding.Check alignment.Check wiring connections.Re-commission actuator (Fuel curve will be lost).Replace actuator

VFD Not At Purge VFD did not reach purge position.

Check motor for binding.Check wiring connections.Re-commission (Fuel curve will be lost).Replace drive

XXX Actuator Not At Lightoff XXX actuator did not reach Lightoff position.

Check actuator for binding.Check alignment.Check wiring connections.Re-commission actuator (Fuel curve will be lost).Replace actuator

Feedwater Temperature Sensor Failure (steam boilers)




Economizer Outlet Temperature Sensor Failure (steam boilers)




Stack Temperature Econ Out Sensor Failure (steam boilers)






6-14 Part No. 750-342


Economizer Inlet Temperature Sensor Failure (steam boilers)




I:8.0 Sensor Failure (user defined analog input)NOTE: All channels on slot 8, if user defined, will have this alarm for the specific channel.



1. Check sensor.2. Check wiring.3. Measure analog signal 4-20ma is valid.4. View analog input Raw value on the HMI PLC I/O status screen.5. Disable Alarms for the channel

I:8.0 Low Alarm (user defined analog input)NOTE: All channels on slot 8, if user defined, will have this alarm for the specific channel.

. I:8/0 Scaled Value is below low alarm setting.

1. Check wiring.2. Adjust Alarm Limit for Analog Input3. Measure analog signal 4-20ma is valid.4. View analog input Raw value on the HMI PLC I/O status screen.5. Disable Alarms for the channel

I:8.0 High Alarm (user defined analog input)NOTE: All channels on slot 8, if user defined, will have this alarm for the specific channel.

. I:8/0 Scaled Value is above high alarm setting.

1. Check wiring.2. Adjust Alarm Limit for Analog Input3. Measure analog signal 4-20ma is valid.4. View analog input Raw value on the HMI PLC I/O status screen.5. Disable Alarms for the channel

Mix O2 Sensor Calibration Failed

Mix O2 analyzer calibration failed.

MixO2 signal (input I:8/2) must be between 4 and 6.5 VDC during calibration

Check wiring.Repeat Calibration.

Stack Pressure Transmitter Failed

With Draft Control enabled Sensor analog signal is either too low or too high.


1. Check Draft Signal.2. Check wiring.3. Measure analog signal 4-20ma is valid.

Stack Pressure High With Draft Control enabled, Pressure exceeds alarm setpoint.

With draft controlenabled, stack pressure I:6.7(draft) is higherthan high alarm set point

1. Check alarm set point.2. Check draft control.3. Check outlet damper

Stack Damper Not Open With Draft Control enabled Stack damper failed toOpen to Full Open Limit Switch

With draft controlenabled, stackdamper Input I:7.0 must be provenopen before burner can start

1. Make sure draft control is in “Auto” Mode2. Check wiring.3. Check Damper Open Limit Switch

Econ 2nd Stage Outlet Water Temp Sensor Failure

With 2 Stage Econ selected, sensor analog signal is either too low or too high.





Part No. 750-342 6-15


Econ 2nd Stage Outlet Water Temp High

With 2 Stage Econ selected, Outlet Water Temp exceeds alarm setpoint

With With 2 Stage Econ enabled, Outlet Water Temp is higherthan high alarm set point

1. Check alarm set point.2. Check 2 stage econ control.

VFD Ethernet Communication Error

VFD Not communicating to the PLC

PLC MSG instruction is in Error.

Verify Ethernet cabling.Verify Ethernet communications to VFD.Set IP address on the VFD to match the Ethernet Config on the HMI.Verify that the Ethernet cable is connected to the Ethernet card and NOT to the built in Modbus port.Verify the Ethernet connector from the Ethernet card to the Drive is connected.

VFD Drive Fault/Alarm Blower Motor VFD alarm. VFD option is selected and no power to PLC input I2/3

1. Check VFD for fault and alarms (see VFD manual for corrective actions)2. Check wiring to input 2 on slot 3. Check VFD parameters.Check Analog Signal wiring 4-20ma control and feedback.Verify VFD digital outputs relay status



6-16 Part No. 750-342

Section 7Parts

PLC & I/O

*1 Required; 2nd optional

HMI

Electrical

Qty Description CB Part Number1 Processor 1769-L33ER 833-05288-0001 Power Supply 1769-PA2 833-02834-0001 Modbus Card 1769-SM2 833-03099-000* Digital Inputs - 1769-IA16 833-02842-0001 Digital Outputs - 1769-OW8I 833-02872-0001 Analog Inputs - 1769-IF4 833-02835-000* Analog Outputs - 1769-OF4 833-09946-000* Analog Input Module - 1769-IF8 833-03106-0001 End Cap Right - 1769-ECR 833-02838-000

Qty Description CB Part Number1 7 inch Color Panel View Plus 817-04863-000

1 PV Plus Hawk Label, 7 Inch 118-03998-000

OPTIONAL:

1 10 Inch Color Panel View Plus 833-03512-000

1 Panel View Plus Hawk Label, 10 Inch 118-03997-000

Qty Description CB Part Number2 24V DC Power Supply - 120W 832-02404-000

10 Shielded Cable 950-00101-000

2 Relay, Terminal Block 833-03060-000

4 Din Rail, 1M Length, 1492-199-DR1 832-01951-000

1 Operator, 2 Position 836-00620-000

1 Contact Block, SPDT 836-00623-000

1 Alarm Bell 817-00239-000


Section 7 — Parts Hawk 4000

Parallel Positioning Actuators

Ethernet

Steam Transmitters

Temperature Transmitters

Qty Description CB Part NumberWITH QUICK CONNECT WITHOUT QUICK CONNECT

1 Modbus FX04-1, 3 ft-lb (4 N-m)* 945-00259-000 269-00221-000

1 Modbus FX20-1, 15 ft-lb (20 N-m)** 945-00260-000 269-00222-000

1 Modbus FX50-1, 37 ft-lb (50 N-m) 945-00261-000 269-00223-000

2 Modbus Actuator Cable Connector 826-00206-000

50 Modbus Actuator Cable 826-00205-000*(Use on Fuel and FGR valves, except in High Torque applications)

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

Qty Description CB Part NumberHIRSHMAN ABSTRATIX

1 Ethernet Switch, 5 Port 833-02862-000 833-09181-000

1 Ethernet Switch, Industrial 8 Port 833-02857-000 833-09163-000

Qty Description CB Part Number1 Steam 0-15 PSIG, 4-20ma 817-04866-000

1 Steam 0-150 PSIG, 4-20ma 817-04867-000

1 Steam 0-300 PSIG, 4-20ma 817-04868-000

1 Steam 0-500 PSIG, 4-20ma 817-04869-000

Smart transmitters, optional:

1 Steam 0-15 PSIG, 4-20ma 817-04873-000

1 Steam 0-150 PSIG, 4-20ma 817-04874-000

1 Steam 0-250 PSIG, 4-20ma 817-04875-000

1 Steam 0-300 PSIG, 4-20ma 817-04876-000

1 Steam 0-350 PSIG, 4-20ma 817-04877-000

1 Steam 0-400 PSIG, 4-20ma 817-04878-000

Qty Description CB Part Number1 Supply Water (Section 4 boiler) 817-09776-000

1 Supply Water (Section 1 boiler) 817-09778-000

Comb. Air/Outdoor Temp/Stack 817-05166-000

Shell/Economizer In and Out/Return Water 817-05167-000

1 Return Water 817-09777-000

7-2 Part No. 750-342

Hawk 4000 Section 7 — Parts

Flame Safeguard

Stack Light

FLAME SAFEGUARD KITS Qty Description CB Part NumberCB-780E w / iR Scanner CB-780E w / IR Scanner Kit 880-02117-000

1 CB-780 Programmer 833-03517-000

1 Wiring Sub-Base 833-02725-000

1 Infared Amplifier 833-03495-000

1 Purge Timer Card 833-02730-000Not Part of 880-Kit 1 Scanner IR 817-1742 817-04133-000

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

1 CB-780 Programmer 833-03517-000

1 Wiring Sub-Base 833-02725-000

1 U.V. Amplifier 833-02724-000

1 Purge Timer Card 833-02730-000Not Part of 880-Kit 1 Flame Detector UV 817-01743-000

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

1 Chassis/Amplifier 833-03708-000

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

1 Programmer 833-03143-000

1 Display 833-03151-000

1 ED-512 communications cable 4 foot long 833-03516-000Not Part of 880-Kit 1 IR Scanner 817-2261 817-01933-000

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

1 Chassis/Amplifier 833-03135-000

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

1 Programmer 833-03143-000

1 Display 833-03151-000

1 ED-512 communications cable 4 foot long 833-03516-000Not Part of 880-Kit 1 UV Detector 817-02262-000

Standard Parts - Next 4 parts required for one standard unit.

Qty Description CB Part Number1 Base 881-00364-000

1 Red Module 881-00361-000

1 Blue Module 881-00369-000

1 Green Module 881-00362-000

Optional

1 Yellow Module 881-00363-000

1 Audible Alarm Module* 881-00370-000

*Piezo alarm replaces the standard alarm bell. Check insurance requirements before eliminating bell.

Part No. 750-342 7-3

Section 7 — Parts Hawk 4000

Dual Fuel Kit

O2 Trim

Outdoor Reset

Qty Description CB Part NumberBundled Kit - Gas Oil Selector 880-02112-000

1 Name Plate 118-01381-000

1 Contact Block, SPDT 836-00623-000

1 Operator, 3 Position 836-00627-000

Qty Description CB Part NumberO2 Kit Yokogawa 880-02111-000

1 O2 Probe and Analyzer 985-00130-000

1 Mounting Kit 656-07576-000

25 Shielded Cable -25 950-00101-000

1 Combustion Air Temperature Sensor 832-02091-000

25 Thermocouple wire -25 950-00414-000

O2 Kit CB 880-02124-000

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


1 O2 Sampling Probe Housing Assembly 040-00735-000

O2 Trim Gas/Oil - NO PP Kit 880-02125-000

1 Oxygen Analyzer, Digital, Yokogawa Model #ZR202G-040 985-00130-000

1 Mounting Kit 656-07576-000

25 Shielded Cable -25 950-00101-000


25 Thermocouple wire -25 950-00414-000

1 O2 Trim Pneumatic Panel 283-03183-000

1 Air Cylinder Assy O2 Trim System

1 Outdoor Reset Thermocouple Option Consists of 832-1744, 008-2998,& 035-364

7-4 Part No. 750-342

Hawk 4000 APPENDIX A

APPENDIX A — HAWK 4000 MASTER TAG LIST

Items in BOLD are write tags

FPC-N34 FPC-N35

PLC Tagname

Point Name BACnet Data Type

BACnet Object Id

N2 Data Type

N2 Point Address

Modbus Register

Lon Name Lon SNVT Type

AB[0].0 Drive Fault BI 1 DI 1 10001 nvoDrvFlt_XXX SNVT_switch

AB[0].1 Modbus Comm Error BI 2 DI 2 10002 nvoModCmEr_XXX SNVT_switch

AB[0].2 Low Water BI 3 DI 3 10003 nvoLoater_XXX SNVT_switch

AB[0].3 Burner Control Alarm BI 4 DI 4 10004 nvoBrnCtrAlm_XXX SNVT_switch

AB[0].4 Boiler Limits Open BI 5 DI 5 10005 nvoBlrLimOpn_XXX SNVT_switch

AB[0].5 High Stack Temp. Alarm BI 6 DI 6 10006 nvoHiStkTpAl_XXX SNVT_switch

AB[0].6 High Stack Temp. Shutdown BI 7 DI 7 10007 nvoHiStTpShd_XXX SNVT_switch

AB[0].7 External Interlock BI 8 DI 8 10008 nvoExtIntrlk_XXX SNVT_switch

AB[0].8 PLC I/O module fault BI 9 DI 9 10009 nvoIOModFlt_XXX SNVT_switch

AB[0].9 Steam Sensor Fail BI 10 DI 10 10010 nvoStmSenFl_XXX SNVT_switch

AB[0].10 Air Actuator Out Of Position Alarm BI 11 DI 11 10011 nvoArAcPosAl_XXX SNVT_switch

AB[0].11 NG Actuator Out Of Position Alarm BI 12 DI 12 10012 nvoNGAcPosAl_XXX SNVT_switch

AB[0].12 F/A Ratio Controller Fault BI 13 DI 13 10013 nvoFARatCtFl_XXX SNVT_switch

AB[0].13 No Fuel Selected BI 14 DI 14 10014 nvoNoFlSel_XXX SNVT_switch

AB[0].14 Low ControlLogix Battery BI 15 DI 15 10015 nvoLoPLCBat_XXX SNVT_switch

AB[0].15 Non Recycle Limit Relay Fail BI 16 DI 16 10016 nvoNoRcLmRlF_XXX SNVT_switch

AB[1].0 Recyle Limit Relay Fail BI 17 DI 17 10017 nvoRecLmRlFl_XXX SNVT_switch

AB[1].1 Remote Modulation Signal Fail BI 18 DI 18 10018 nvoRemMdSgFl_XXX SNVT_switch

AB[1].2 Header Pressure Sensor Fail BI 19 DI 19 10019 nvoHdPrSnFl_XXX SNVT_switch

AB[1].3 Temperature Channel 0-5 Failure BI 20 DI 20 10020 nvoTpCh0_5Fl_XXX SNVT_switch

AB[1].4 Low O2 Alarm BI 21 DI 21 10021 nvoLoO2Alm_XXX SNVT_switch

AB[1].5 High Limit Alarm BI 22 DI 22 10022 nvoHiLimAlm_XXX SNVT_switch

AB[1].6 ALWCO BI 23 DI 23 10023 nvoALWCO_XXX SNVT_switch

AB[1].7 Low Gas Pressure/Low Oil Temp BI 24 DI 24 10024 nvoLoGsPrOTp_XXX SNVT_switch

AB[1].8 High Gas Pressure/High Oil Temp BI 25 DI 25 10025 nvoHiGsPrOTp_XXX SNVT_switch

AB[1].9 Low Oil Pressure BI 26 DI 26 10026 nvoLoOilPrs_XXX SNVT_switch

AB[1].10 High Oil Pressure BI 27 DI 27 10027 nvoHiOilPrs_XXX SNVT_switch

AB[1].11 Oil Drawer Switch Not Made BI 28 DI 28 10028 nvoOilDrwrSw_XXX SNVT_switch

AB[1].12 Low Atomizing Air Pressure BI 29 DI 29 10029 nvoLoAtmArPr_XXX SNVT_switch

AB[1].13 Low Combustion Air Pressure BI 30 DI 30 10030 nvoLoComArPr_XXX SNVT_switch

AB[1].14 AUX Alarm 1 - Stack Damper High Pressure (next Gen)

BI 31 DI 31 10031 nvoAUXAlm1_XXX SNVT_switch

AB[1].15 AUX Alarm 2 BI 32 DI 32 10032 nvoAUXAlm2_XXX SNVT_switch

AB[2].0 Blower On BI 33 DI 33 10033 nvoBlwOn_XXX SNVT_switch

AB[2].1 Purge Input BI 34 DI 34 10034 nvoPrgIn_XXX SNVT_switch

AB[2].2 Release To Modulate Input BI 35 DI 35 10035 nvoRel2ModIn_XXX SNVT_switch

AB[2].3 Low Fire Switch BI 36 DI 36 10036 nvoLoFirSw_XXX SNVT_switch

AB[2].4 High Fire Switch BI 37 DI 37 10037 nvoHiFirSw_XXX SNVT_switch

AB[2].5 Ready to start/Limits Closed BI 38 DI 38 10038 nvoRdy2Str_XXX SNVT_switch

AB[2].6 External Start Interlock BI 39 DI 39 10039 nvoExtStInlk_XXX SNVT_switch

AB[2].7 ALFCO BI 40 DI 40 10040 nvoALFCO_XXX SNVT_switch

AB[2].8 Pilot BI 41 DI 41 10041 nvoPilot_XXX SNVT_switch

AB[2].9 Main Fuel Valve Open BI 42 DI 42 10042 nvoMnFlVlvOp_XXX SNVT_switch

AB[2].10 Fuel 1 Selected BI 43 DI 43 10043 nvoFl1Sel_XXX SNVT_switch


AB[2].12 Heart Beat To BMS BI 45 DI 45 10045 nvoHrtBtBMS_XXX SNVT_switch

AB[2].13 LWCO Shutdown BI 46 DI 46 10046 nvoLWCOShdn_XXX SNVT_switch

AB[2].14 Remote Enable Input BI 47 DI 47 10047 nvoRmEnblInp_XXX SNVT_switch

Part No. 750-342 A-1

APPENDIX A Hawk 4000

AB[2].15 Burner Switch On BI 48 DI 48 10048 nvoBrnSw_XXX SNVT_switch

AB[3].0 Recycle Limit Relay BI 49 DI 49 10049 nvoRecLimRel_XXX SNVT_switch

AB[3].1 External Device Start BI 50 DI 50 10050 nvoExtDevSt_XXX SNVT_switch

AB[3].2 Non Recycle Limit Relay BI 51 DI 51 10051 nvoNoRecLmRl_XXX SNVT_switch

AB[3].3 Drive to Low Fire (FARC) BI 52 DI 52 10052 nvoDrv2LoFir_XXX SNVT_switch

AB[3].4 Start Slave Blr (2 Blr LL) BI 53 DI 53 10053 nvoStrtSlvBl_XXX SNVT_switch

AB[3].5 Load Demand Output BI 54 DI 54 10054 nvoLdDemOut_XXX SNVT_switch

AB[3].6 Alarm Output BI 55 DI 55 10055 nvoAlmOut_XXX SNVT_switch

AB[3].7 Boiler Ready (LL) BI 56 DI 56 10056 nvoBlrRdyLL_XXX SNVT_switch

AB[3].8 Boiler Load Demand BI 57 DI 57 10057 nvoBlrLdDem_XXX SNVT_switch

AB[3].9 Firing Rate Remote/Llag BI 58 DI 58 10058 nvoFrRatRmLL_XXX SNVT_switch

AB[3].10 Firing Rate Manual BI 59 DI 59 10059 nvoFirRatMan_XXX SNVT_switch

AB[3].11 Firing Rate Auto BI 60 DI 60 10060 nvoFrRatAuto_XXX SNVT_switch

AB[3].12 Hot Stand By BI 61 DI 61 10061 nvoHotStndBy_XXX SNVT_switch

AB[3].13 Warm Up BI 62 DI 62 10062 nvoWarmUp_XXX SNVT_switch


AB[3].15 Aux Alarm 3 BI 64 DI 64 10064 nvoAuxAlm3_XXX SNVT_switch

AB[4].0 Steam or Hot Water 1 = Steam BI 65 DI 65 10065 nvoStm_HWtr_XXX SNVT_switch

AB[4].1 Level Master Present BI 66 DI 66 10066 nvoLvlMstPrs_XXX SNVT_switch

AB[4].2 Variable Speed Drive Present BI 67 DI 67 10067 nvoVarSpDrPr_XXX SNVT_switch

AB[4].3 Economizer Present BI 68 DI 68 10068 nvoEcPrs_XXX SNVT_switch

AB[4].4 Combustion Air Temp. Present BI 69 DI 69 10069 nvoCmArTpPrs_XXX SNVT_switch

AB[4].5 Economizer Inlet FW Sensor Present BI 70 DI 70 10070 nvoEInFwSnPr_XXX SNVT_switch

AB[4].6 O2 Analyzer Present BI 71 DI 71 10071 nvoO2AnlzrPr_XXX SNVT_switch

AB[4].7 Feedwater or Return Temp. Present BI 72 DI 72 10072 nvoFdWRtTpPr_XXX SNVT_switch

AB[4].8 Outdoor Reset Selected BI 73 DI 73 10073 nvoOutResSel_XXX SNVT_switch

AB[4].9 Parallel Positioning Selected BI 74 DI 74 10074 nvoParPosSel_XXX SNVT_switch

AB[4].10 Two Boiler Lead Lag Master Select BI 75 DI 75 10075 nvo2BLLMstSl_XXX SNVT_switch

AB[4].11 Two Boiler Lead Lag Slave Select BI 76 DI 76 10076 nvo2BLLSlvSl_XXX SNVT_switch

AB[4].12 Master Panel Select BI 77 DI 77 10077 nvoMstPnlSel_XXX SNVT_switch

AB[4].13 Hot Stand By Select BI 78 DI 78 10078 nvoHotStbySl_XXX SNVT_switch

AB[4].14 Dual Setpoint Select BI 79 DI 79 10079 nvoDualSPSel_XXX SNVT_switch

AB[4].15 Slot 8 Ch 0 Analog Input Selected BI 80 DI 80 10080 nvoSlCh0AISl_XXX SNVT_switch




AB[5].3 Honeywell or Fireye 1 = Fireye BI 84 DI 84 10084 nvoHnywFreye_XXX SNVT_switch

AB[5].4 High Water Alarm BI 85 DI 85 10085 nvoHiWtrAlm_XXX SNVT_switch

AB[5].5 Oil Actuator Out Of Position Alarm BI 86 DI 86 10086 nvoOlAcPsAlm_XXX SNVT_switch

AB[5].6 FGR Actuator Out Of Position Alarm BI 87 DI 87 10087 nvoFGRAcPsAl_XXX SNVT_switch

AB[5].7 Air Actuator Feedback Fail Low Alarm BI 88 DI 88 10088 nvoAAcFdLoAl_XXX SNVT_switch

AB[5].8 Air Actuator Feedback Fail High Alarm BI 89 DI 89 10089 nvoAAcFdHiAl_XXX SNVT_switch

AB[5].9 NG Actuator Feedback Fail Low Alarm BI 90 DI 90 10090 nvoNGAFdLoAl_XXX SNVT_switch

AB[5].10 NG Actuator Feedback Fail High Alarm BI 91 DI 91 10091 nvoNGAFdHiAl_XXX SNVT_switch

AB[5].11 Oil Actuator Feedback Fail Low Alarm BI 92 DI 92 10092 nvoOilFdLoAl_XXX SNVT_switch

AB[5].12 Oil Actuator Feedback Fail High Alarm BI 93 DI 93 10093 nvoOilFdHiAl_XXX SNVT_switch

AB[5].13 FGR Actuator Feedback Fail Low Alarm BI 94 DI 94 10094 nvoFGRFdLoAl_XXX SNVT_switch

AB[5].14 FGR Actuator Feedback Fail High Alarm BI 95 DI 95 10095 nvoFGRFdHiAl_XXX SNVT_switch

AB[5].15 VSD Deviation Alarm BI 96 DI 96 10096 nvoVSDDevAlm_XXX SNVT_switch

AB[6].0 Increase MSG Register Size Bit (Cleaver Brooks Only)

BI 97 DI 97 10097 nvoIncRegSiz_XXX SNVT_switch

AB[6].1 Air/Fuel Deviation Alarm BI 98 DI 98 10098 nvoArFlDevAl_XXX SNVT_switch

AB[6].2 2nd Stage CEC Economizer Selected BI 99 DI 99 10099 nvo2StCECEcS_XXX SNVT_switch

A-2 Part No. 750-342


AB[6].3 Fuel3 Actuator 1 Out Of Position Alarm BI 100 DI 100 10100 nvoFl3AcPsAl_XXX SNVT_switch

AB[6].4 Fuel3 Actuator 1 Feedback Fail Low Alarm

BI 101 DI 101 10101 nvoFl3AFdLoA_XXX SNVT_switch

AB[6].5 Fuel3 Actuator 1 Feedback Fail High Alarm

BI 102 DI 102 10102 nvoFl3AFdHiA_XXX SNVT_switch

AB[6].6 Stack Pressure Input Fail BI 103 DI 103 10103 nvoStkPrInFl_XXX SNVT_switch

AB[6].7 High Stack Pressure Alarm BI 104 DI 104 10104 nvoHiStkPrAl_XXX SNVT_switch

AB[6].8 Stack Damper Not Open Alarm BI 105 DI 105 10105 nvoStDpNtOAl_XXX SNVT_switch

AB[6].9 O2 Calibration Failed BI 106 DI 106 10106 nvoO2ClRtFld_XXX SNVT_switch

AB[6].10 Low Steam Pressure/Water Temp Alarm BI 107 DI 107 10107 nvoLoStPWTAl_XXX SNVT_switch

AB[6].11 Processor Test Fail Alarm BI 108 DI 108 10108 nvoPrTstFlAl_XXX SNVT_switch

AB[6].12 O2 Trim Internal Alarm BI 109 DI 109 10109 nvoO2TrmInAl_XXX SNVT_switch

AB[6].13 Firetube or Flextube 1 = Flextube BI 110 DI 110 10110 nvoFir_FlxTb_XXX SNVT_switch

AB[6].14 Reserved for Cleaver Brooks BI 111 DI 111 10111 nvoAB_6_14_XXX SNVT_switch

AB[6].15 VSD Limits Internal Alarm BI 112 DI 112 10112 nvoVSDLmInAl_XXX SNVT_switch

AB[7].0 Gas Actuator #2 Out Of Position Alarm BI 113 DI 113 10113 nvoGsAc2PsAl_XXX SNVT_switch

AB[7].1 Gas Actuator #2 Feedback Fail Low Alarm BI 114 DI 114 10114 nvoGsAc2LoAl_XXX SNVT_switch

AB[7].2 Gas Actuator #2 Feedback Fail High Alarm

BI 115 DI 115 10115 nvoGsAc2HiAl_XXX SNVT_switch

AB[7].3 Actuator Modbus Communication Error BI 116 DI 116 10116 nvoAcModCmEr_XXX SNVT_switch

AB[7].4 Air Actuator Modbus Comm Error Node 1 BI 117 DI 117 10117 nvoAAcMdCEr1_XXX SNVT_switch

AB[7].5 Gas Actuator Modbus Comm Error Node 2

BI 118 DI 118 10118 nvoGsAMdCEr2_XXX SNVT_switch

AB[7].6 Gas Act #2 Modbus Comm Error Node 3 BI 119 DI 119 10119 nvoGsA2MdCE3_XXX SNVT_switch

AB[7].7 Oil Actuator Modbus Comm Error Node 5 BI 120 DI 120 10120 nvoOAcMdCEr5_XXX SNVT_switch

AB[7].8 FGR Actuator Modbus Comm Error Node 7

BI 121 DI 121 10121 nvoFGRAMdCE7_XXX SNVT_switch

AB[7].9 Reserved BI 122 DI 122 10122 nvoAB_7_9_XXX SNVT_switch

AB[7].10 Reserved BI 123 DI 123 10123 nvoAB_7_10_XXX SNVT_switch

AB[7].11 Second Stage Outlet Water Temp Sensor Failed

BI 124 DI 124 10124 nvo2SOtWTSnF_XXX SNVT_switch

AB[7].12 Water Temperature Second Stage Out High

BI 125 DI 125 10125 nvoWtTp2SOtH_XXX SNVT_switch

AB[7].13 Air Actuator Manual Override Pushbutton Pressed

BI 126 DI 126 10126 nvoAAcMnOBPr_XXX SNVT_switch

AB[7].14 Gas Actuator #1 Manual Override Pushbutton Pressed

BI 127 DI 127 10127 nvoGAc1MOBPr_XXX SNVT_switch

AB[7].15 Gas Actuator #2 Manual Override Pushbutton Pressed

BI 128 DI 128 10128 nvoGAc2MOBPr_XXX SNVT_switch

AB[8].0 Oil Actuator Manual Override Pushbutton Pressed

BI 129 DI 129 10129 nvoOAcMnOBPr_XXX SNVT_switch

AB[8].1 FGR Actuator Manual Override Pushbutton Pressed

BI 130 DI 130 10130 nvoFGRAMnOBP_XXX SNVT_switch

AB[8].2 Fuel 3 Actuator #1 Manual Override Pushbutton Pressed

BI 131 DI 131 10131 nvoFl3A1MOBP_XXX SNVT_switch

AB[8].3 Fuel 3 Actuator #2 Manual Override Pushbutton Pressed

BI 132 DI 132 10132 nvoFl3A2MOBP_XXX SNVT_switch

AB[8].4 Communication from BMS Failed BI 133 DI 133 10133 nvoComBMSFld_XXX SNVT_switch

AB[8].5 Combustion Air Pressure High BI 134 DI 134 10134 nvoLoO2Shdn_XXX SNVT_switch

AB[8].6 Water Flow Low BI 135 DI 135 10135 nvoAB_8_6_XXX SNVT_switch

AB[8].7 Water Level Signal Failed BI 136 DI 136 10136 nvoAB_8_7_XXX SNVT_switch

AB[8].8 Remote Setpoint Signal Failed BI 137 DI 137 10137 nvoAB_8_8_XXX SNVT_switch

AB[8].9 Low O2 Shutdown BI 138 DI 138 10138 nvoAB_8_9_XXX SNVT_switch

AB[8].10 Air Actuator Fault BI 139 DI 139 10139 nvoAB_8_10_XXX SNVT_switch

AB[8].11 Fuel 1 Actuator 1 Fault BI 140 DI 140 10140 nvoAB_8_11_XXX SNVT_switch




AB[8].15 FGR Actuator Fault BI 144 DI 144 10144 nvoAB_8_15_XXX SNVT_switch

AB[9].0 Fuel 2 Actuator 2 Position Deviation BI 145 DI 145 10145 nvoAB_9_0_XXX SNVT_switch

AB[9].1 Fuel 2 Actuator 2 Feedback Low BI 146 DI 146 10146 nvoAB_9_1_XXX SNVT_switch

Part No. 750-342 A-3


AB[9].2 Fuel 2 Actuator 2 Feedback High BI 147 DI 147 10147 nvoAB_9_2_XXX SNVT_switch

AB[9].3 Fuel 2 Actuator 2 Manual PB Pressed BI 148 DI 148 10148 nvoAB_9_3_XXX SNVT_switch

AB[9].4 VFD Feedback Low BI 149 DI 149 10149 nvoAB_9_4_XXX SNVT_switch

AB[9].5 VFD Feedback High BI 150 DI 150 10150 nvoAB_9_5_XXX SNVT_switch

AB[9].6 Master PIDE Instruction Fault BI 151 DI 151 10151 nvoAB_9_6_XXX SNVT_switch

AB[9].7 FGEN Fault BI 152 DI 152 10152 nvoAB_9_7_XXX SNVT_switch

AB[9].8 Outdoor Temp Sensor Failed BI 153 DI 153 10153 nvoAB_9_8_XXX SNVT_switch

AB[9].9 Combustion Air Temp Sensor Failed BI 154 DI 154 10154 nvoAB_9_9_XXX SNVT_switch

AB[9].10 Yokogawa O2 Sensor Fault BI 155 DI 155 10155 nvoAB_9_10_XXX SNVT_switch

AB[9].11 Mix O2 Sensor Calibration Fail BI 156 DI 156 10156 nvoAB_9_11_XXX SNVT_switch

AB[9].12 Mix O2 Enable BI 157 DI 157 10157 nvoAB_9_12_XXX SNVT_switch

AB[9].13 Air Actuator Not at Purge BI 158 DI 158 10158 nvoAB_9_13_XXX SNVT_switch

AB[9].14 VFD Not at Purge BI 159 DI 159 10159 nvoAB_9_14_XXX SNVT_switch

AB[9].15 Hawk 1000 system BI 160 DI 160 10160 nvoAB_9_15_XXX SNVT_switch

AB[10].0 Hawk 4500 - Increase MSG Size of Bool to 15

BI 161 DI 161 10161

AB[10].1 Stack Temp Econ Out Sensor Failed BI 162 DI 162 10162

AB[10].2 Econ In Water Temp Sensor Failed BI 163 DI 163 10163

AB[10].3 Fuel 3 Actuator 1 Fault BI 164 DI 164 10164

AB[10].4 Fuel 3 Actuator 2 Position Deviation BI 165 DI 165 10165

AB[10].5 Fuel 3 Actuator 2 Feedback Low BI 166 DI 166 10166

AB[10].6 Fuel 3 Actuator 2 Feedback High BI 167 DI 167 10167

AB[10].7 Fuel 3 Actuator 2 Fault BI 168 DI 168 10168

AB[10].8 Fuel 3 Actuator 1 Modbus Comm Error BI 169 DI 169 10169



AB[10].11 Return Temp Sensor Failed BI 172 DI 172 10172

AB[10].12 Water Shell Temp Sensor Failed BI 173 DI 173 10173

AB[10].13 Feedwater/Econ Out Temp Sensor Failed BI 174 DI 174 10174

AB[10].14 Feedwater Level Control Option Selected BI 175 DI 175 10175

AB[10].15 BI 176 DI 176 10176

AB[11].0 Slot8 Ch0 Bad Quality BI 177 DI 177 10177

AB[11].1 Slot8 Ch0 Low Alarm BI 178 DI 178 10178

AB[11].2 Slot8 Ch0 High Alarm BI 179 DI 179 10179




AB[11].6 Slot8 Ch2 Bad Quality/Mix O2 Signal Fail BI 183 DI 183 10183









AB[11].15 Spare BI 192 DI 192 10192







A-4 Part No. 750-342





AB[12].9 VFD EtherNet Comm Error BI 202 DI 202 10202

AB[12].10 Slot 8 Ch 4 Analog Input Selected BI 203 DI 203 10203




AB[12].14 BI 207 DI 207 10207

AB[12].15 BI 208 DI 208 10208

AB[13].0 Air Actuator 2 Position Deviation BI 209 DI 209 10209

AB[13].1 Air Actuator 2 Feedback Low BI 210 DI 210 10210

AB[13].2 Air Actuator 2 Feedback High BI 211 DI 211 10211

AB[13].3 Air Actuator 2 Modbus Comm Error (Node 4)

BI 212 DI 212 10212

AB[13].4 Air Actuator 2 Manual PB Pressed BI 213 DI 213 10213

AB[13].5 Air Actuator 2 Fault BI 214 DI 214 10214

AB[13].6 Air Actuator 2 Not At Purge BI 215 DI 215 10215

AB[13].7 Air Actuator 2 Not At Lightoff BI 216 DI 216 10216

AB[13].8 Air Actuator Not At Lightoff BI 217 DI 217 10217

AB[13].9 Fuel Actuator 1 Not At Lightoff BI 218 DI 218 10218

AB[13].10 Fuel Actuator 2 Not At Lightoff BI 219 DI 219 10219

AB[13].11 FGR Actuator Not At Lightoff BI 220 DI 220 10220

AB[13].12 VFD Not At Lightoff BI 221 DI 221 10221

AB[13].13 BI 222 DI 222 10222

AB[13].14 BI 223 DI 223 10223

AB[13].15 BI 224 DI 224 10224

AB[14].0 NOx Analzer Present BI 225 DI 225 10225

AB[14].1 NOx Trim Enabled BI 226 DI 226 10226

AB[14].2 NOx Sensor Calibration Failed Alarm BI 227 DI 227 10227

AB[14].3 NOx Sensor Comms Not OK BI 228 DI 228 10228

AB[14].4 BI 229 DI 229 10229

AB[14].5 BI 230 DI 230 10230

AB[14].6 BI 231 DI 231 10231

AB[14].7 BI 232 DI 232 10232

AB[14].8 BI 233 DI 233 10233

AB[14].9 BI 234 DI 234 10234

AB[14].10 BI 235 DI 235 10235

AB[14].11 BI 236 DI 236 10236

AB[14].12 BI 237 DI 237 10237

AB[14].13 BI 238 DI 238 10238

AB[14].14 BI 239 DI 239 10239

AB[14].15 BI 240 DI 240 10240

AR[0] Flame Strength Honeywell AI 1 AI 1 30001 nvoFlmStrHny_XXX SNVT_count_f

AR[1] Combustion Air Fan Speed AI 2 AI 2 30003 nvoCmArFnSpd_XXX SNVT_count_f

AR[2] AR[2] AI 3 AI 3 30005 nvoAR_2__XXX SNVT_count_f

AR[3] Boiler Efficiency AI 4 AI 4 30007 nvoBlrEff_XXX SNVT_lev_percent

AR[4] Firing Rate AI 5 AI 5 30009 nvoFirRat_XXX SNVT_lev_percent

AR[5] O2 Level AI 6 AI 6 30011 nvoO2Lvl_XXX SNVT_lev_percent

AR[6] SP Steam Pressure/Water Temp AI 7 AI 7 30013 nvoSPStPWtTp_XXX SNVT_count_f

AR[7] Water Level AI 8 AI 8 30015 nvoWtrLvl_XXX SNVT_press_f

AR[8] Steam Pressure or Hot Water Temp AI 9 AI 9 30017 nvoStPrHWTmp_XXX SNVT_count_f

AR[9] AR[9] AI 10 AI 10 30019 nvoAR_9_XXX SNVT_count_f

Part No. 750-342 A-5


AR[10] Stack Temp Before Economizer AI 11 AI 11 30021 nvoStkTpBfEc_XXX SNVT_temp_p

AR[11] Combustion Air Temp AI 12 AI 12 30023 nvoComAirTmp_XXX SNVT_temp_p

AR[12] Water Temp Shell/Outdoor Temp AI 13 AI 13 30025 nvoWtTpShl_XXX SNVT_temp_p

AR[13] Feedwater Temp/Econ Water Out Temp AI 14 AI 14 30027 nvoFdWtTp_XXX SNVT_temp_p

AR[14] Stack Temp After Econ/Return HW AI 15 AI 15 30029 nvoStkTmpEco_XXX SNVT_temp_p

AR[15] Economizer Water In Temp AI 16 AI 16 30031 nvoEcWtInTmp_XXX SNVT_temp_p

AR[16] AI Slot8Ch0 Value/2Stg Econ Temp IN AI 17 AI 17 30033 nvoAISlCh0Vl_XXX SNVT_count_f

AR[17] AI Slot8Ch1 Value/2Stg Econ Temp OUT AI 18 AI 18 30035 nvoAISlCh1Vl_XXX SNVT_count_f

AR[18] AI Slot8 Ch2 Value (EU) AI 19 AI 19 30037 nvoAISlCh2Vl_XXX SNVT_count_f

AR[19] AI Slot8 Ch3 Value (EU) AI 20 AI 20 30039 nvoAISlCh3Vl_XXX SNVT_count_f

AR[20] Safety Valve Setting or Max Water Temp AI 21 AI 21 30041 nvoSftVlvSet_XXX SNVT_count_f

AR[21] Header Pressure or Temp 2 Boiler LL AI 22 AI 22 30043 nvoHdPrTpBLL_XXX SNVT_count_f

AR[22] SP 2 Boiler LL AI 23 AI 23 30045 nvoSP2BlrLL_XXX SNVT_count_f

AR[23] Boiler Off Point AI 24 AI 24 30047 nvoBlrOffPt_XXX SNVT_count_f

AR[24] Boiler On Point AI 25 AI 25 30049 nvoBlrOnPt_XXX SNVT_count_f

AR[25] Condensate Return Valve Output Command

AI 26 AI 26 30051 nvoCdRtVOtCm_XXX SNVT_lev_percent

AR[26] Makeup Bypass Valve Output Command AI 27 AI 27 30053 nvoMkByVOtCm_XXX SNVT_lev_percent

AR[27] Slot8 Ch0 FLo Total AI 28 AI 28 30055 nvoSlC0FlTo_XXX SNVT_count_f























AI[0] Burner Control Status Line 1 Honeywell AI 52 AI 52 30102 nvoBSt1Hnywl_XXX SNVT_count_f

AI[1] Burner Control Status Line 2 Honeywell AI 53 AI 53 30103 nvoBSt2Hnywl_XXX SNVT_count_f

AI[2] Burner Control Status Line 1 Fireye AI 54 AI 54 30104 nvoBSt1Freye_XXX SNVT_count_f

AI[3] Burner Control Status Line 2 Fireye AI 55 AI 55 30105 nvoBSt2Freye_XXX SNVT_count_f

AI[4] Flame Signal Fireye AI 56 AI 56 30106 nvoFlSgFrey_XXX SNVT_count_f

AI[5] Fuel 1Type AI 57 AI 57 30107 nvoFl1Type_XXX SNVT_count_f

AI[6] Fuel 2 Type AI 58 AI 58 30108 nvoFl2Type_XXX SNVT_count_f

AI[7] Fuel 3 Type AI 59 AI 59 30109 nvoFl3Type_XXX SNVT_count_f

AI[9] Elapsed Time (First 16 Bits) AI 61 AI 61 30111 nvoElpTm1_XXX SNVT_time_hour

AI[10] Elapsed Time (Second 16 Bits) AI 62 AI 62 30112 nvoElpTm2_XXX SNVT_time_hour

AI[11] Number Of Cycles (First 16 Bits) AI 63 AI 63 30113 nvoNumCyc1_XXX SNVT_count_f

AI[12] Number Of Cycles (Second 16 Bits) AI 64 AI 64 30114 nvoNumCyc2_XXX SNVT_count_f

A-6 Part No. 750-342


AI[13] AI[13] AI 65 AI 65 30115 nvoAI_13_XXX SNVT_count_f

















AD[0] Elapsed Time AI 82 AI 82 30132 nvoElapTim_XXX SNVT_time_hour

AD[1] Number Of Cycles AI 83 AI 83 30134 nvoNumCyc_XXX SNVT_count_f

AWB[0].0 Heart Beat From BMS BV 1 DO 1 00001 nvoHtBtFrBMS_XXX SNVT_switch

AWB[0].1 Rem Start From BMS BV 2 DO 2 00002 nvoRmStFrBMS_XXX SNVT_switch

AWB[0].2 AWB[0]2 BV 3 DO 3 00003 nvoAWB_0_2_XXX SNVT_switch






























AWR[0] Rem Op SP Boiler AV 1 AO 1 40001 nvoRmOpSPBlr_XXX SNVT_count_f

Part No. 750-342 A-7


AWR[1] Rem Firing Rate AV 2 AO 2 40003 nvoRemFirRat_XXX SNVT_lev_percent

AWR[2] Rem Op SP 2 boiler Lead/Lag AV 3 AO 3 40005 nvoRmOSP2BLL_XXX SNVT_count_f

AWR[3] AWR[3] AV 4 AO 4 40007 nvoAWR_3_XXX SNVT_count_f







A-8 Part No. 750-342

Hawk 4000 APPENDIX B

APPENDIX B — LOADING A PLC PROGRAM

Loading a Hawk PLC program from an SD card to an L33ER or L24ER processor.

Required Hardware:

• SD card: Every PLC processor should come with an SD card from Rockwell Automation.

• SD Card Reader

• Laptop Computer

1.If the PLC program file is in .zip format it must beextracted.

2.Use your computer SD card reader or connect an externalSD card reader to the computer.

3.Select the Logix .zip file and Right mouse click.

4.Select Open with WinZip (or another extraction program)

5.From WinZip select Extract.

6.Navigate to the location of the SD card that will be used to transfer the Logix folder to the PLC. SelectExtract.

Part No. 750-342 B-1

APPENDIX B Hawk 4000

7.Close the WinZip program.

8.The Logix folder should now be extracted to the SD card. The logix folder must be at the root directory ofthe SD card. No other files should be present on the SD card. Use Windows Explorer to verify the Logix folderon the SD card.

9.Use the Remove Hardware tool to safely eject the SD card from the computer.

B-2 Part No. 750-342

Hawk 4000 APPENDIX B

10. Install the SD card into the PLC SD card slot. The PLC switch should be in REM.

11.Cycle power to the PLC.

12.The transfer from the SD card to the PLC processor will begin. Please bepatient while the installation is in progress, the whole process from power upto completion may take up to 3 Minutes. Prematurely ending the SD card loadprocess may render the plc unuseable!

13.During the transfer process the OK Led on the PLC will be solid RED. TheSD Led will begin to flash GREEN indicating that the PLC is reading from theSD card. Upon completion, the RUN and OK Led's should be solid GREEN. Ifrun Led is NOT Solid Green put PLC switch to RUN.

14.Remove the SD card from the PLC SD card slot.

15.If the SD card has come from the factory or if the program was taken fromthe CB Portal, loading from the SD card will install PLC firmware, the PLCprogram, and set the IP address of the PLC to 192.168.1.101.

Part No. 750-342 B-3

e-mail: [email protected] Address: http://www.cleaverbrooks.com

hawk 4000 -...

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