CleaverBrooks Hawk 1000 Operation Manual
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CleaverBrooks Hawk 1000 Operation Manual

CleaverBrooks Hawk 1000 Operation Manual

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Hawk 1000
Boiler Control
Operation Manual
750-366
07/2013

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  • Page 1 Hawk 1000 Boiler Control Operation Manual 750-366 07/2013...
  • Page 2 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.
  • Page 3 Cleaver-Brooks HAWK 1000 Boiler Control Operation Manual Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative Manual Part No. 750-366 07/2013...

  • Page 5: Table Of Contents

    Parts Hawk 1000 Parts List ........7-1...
  • Page 7 Hawk 1000 System Features ........

  • Page 8: Introduction

    Hawk 1000 1.1 Introduction The Cleaver-Brooks HAWK 1000 is an exclusive Boiler Management and Control system specifically designed to integrate the functions of a Programmable Boiler Controller and Burner Management Controller, as well as other boiler operating and ancillary controls. The HAWK 1000 system incorporates a user-friendly, graphical Human Machine Interface (HMI) that displays boiler parameters, fault annunciation and alarm history, as well as providing access to boiler configuration and control functions.

  • Page 9: System Description

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

  • Page 10: Hawk 1000 System Features

    Section 1 — General Hawk 1000 1.3 Hawk 1000 System Features • Burner Control controls burner start and shutdown sequencing and flame and interlock monitoring • Compatible with CB780E and CB120E Burner Controls and Flame Scanners • Boiler Control monitors and displays connected boiler parameters (operating pressure or temperature, stack temperature, shell water temperature, O2% etc.)

  • Page 11: Safety Provisions And 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 1-4. Hawk 1000 Main Menu Part No. 750-366...

  • Page 12: Inputs And Outputs

    Section 1 — General Hawk 1000 1.5 Inputs and Outputs Part No. 750-366...
  • Page 13 Hot Water systems: ........2-6 www.cleaverbrooks.com...

  • Page 14: Overview

    Hawk 1000 2.1 Overview The principal components of the HAWK 1000 Boiler Control System are the Programmable Logic Controller (PLC), Touch Screen Human Machine Interface (HMI), and the Flame Safety Control. The system also includes 24VDC power supplies and various relays and circuit breakers.

  • Page 15: Human-Machine Interface (Hmi)

    Example: Steam Pressure (0-150 PSI) NOTE: The PLC program expects each device to be in a specific slot location. The HAWK 1000 controls will not function unless all devices are properly installed and configured.

  • Page 16: Communications

    2.4 Communications 2.4.1 Modbus Modbus is an open serial protocol used by the HAWK 1000 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 base unit in slot 4.

  • Page 17: Ethernet

    Section 2 — System Components 2.4.2 Ethernet The HAWK 1000 uses Ethernet for several communication functions: • Communication between the PLC and HMI. The Ethernet cable connecting the PLC and HMI can be either a straight through or a crossover type.

  • Page 18: Sensor Inputs

    2.5.1 Steam Systems: Steam Pressure is the primary sensor input to the HAWK 1000 Controller in a Steam System. It transmits a 4-20mA process variable signal to the Controller that is used to control Firing Rate and the Operating Limit Control.
  • Page 19 Power/ Communications LED ......3-10 Moving The Actuator ....... . 3-11 www.cleaverbrooks.com...

  • Page 20: Control Panel Component Checks

    Section 3 — Hardware Checkout Hawk 1000 Important The base unit and expansion modules do not support removal and insertion under power. While the PLC system is under power, any break in the connection between the power supply and the base unit (i.e.

  • Page 21: Panel And Field Wiring Terminations

    Hawk 1000 Section 3 — Hardware Checkout 3.1.2 Panel and Field Wiring Terminations Check that all factory wiring connections are tight and that field wiring terminations are completed and secure. Figure 3-3. Check all wiring and connections 3.1.3 SM2 Module DIP Switch Verify that the SM2 Module DIP switch setting is as shown below (the top switch is to the left, the bottom switch is to the right).

  • Page 22: Burner Control Modbus Address And Baud Rate - Cb780E

    Section 3 — Hardware Checkout Hawk 1000 3.1.4 Burner Control Modbus Address and Baud Rate - CB780E The CB780E Modbus node address should be set to 05 and the baud rate to 9600. Settings are made using the 780E keypad display.
  • Page 23 Hawk 1000 Section 3 — Hardware Checkout Press down arrow key to save changes. Press down arrow key until MB BAUD is displayed. Press ENTER buttons at the same time. Press down arrow to select. Using up or down arrow key select 9600.

  • Page 24: Burner Control Modbus Address And Baud Rate - Cb120E

    Section 3 — Hardware Checkout Hawk 1000 Press down arrow key to save changes. Press ENTER buttons at the same time. Press upper arrow key to exit. 3.1.5 Burner Control Modbus Address and Baud Rate - CB120E The CB120E has built-in Modbus capability; for proper communications the ModBus baud rate and node address need to be correctly set.

  • Page 25: Modbus Actuator Checks

    Hawk 1000 Section 3 — Hardware Checkout Press the <MODE> then the <NEXT> key until the screen displays BAUD RATE. Press <MDFY> and use the <BACK> or <NEXT> key to change to 4800. Press <MDFY> to save. Press the <NEXT> key until UNIT ADDRESS # is displayed. To change the unit address, use the <BACK>...
  • Page 26 Section 3 — Hardware Checkout Hawk 1000 Figure 3-5. SM2 wiring to actuators MODBUS ACTUATORS PLUG WIRED FUEL 1 FUEL 2 ACT. 1 ACT. 1 Figure 3-6. Actuator daisy chain w/ plug connections Part No. 750-366...

  • Page 27: Setting The Modbus Node Address

    Hawk 1000 Section 3 — Hardware Checkout MODBUS ACTUATORS HARD WIRED FUEL 1 FUEL 2 ACT. 1 ACT. 1 Figure 3-7. Actuator daisy chain hard wired 3.2.3 Setting The Modbus Node Address The actuators are required to have unique Modbus node addresses. The node address is set using a rotary style switch located on the actuator front plate.

  • Page 28: Power/ Communications Led

    Section 3 — Hardware Checkout Hawk 1000 Rotary switch - set node address Power/Command LED Figure 3-8. Modbus Actuator Once the node address has been set, the actuator may be powered up. Power must be cycled to the actuator before a new node address setting will be accepted by the actuator.

  • Page 29: Moving The Actuator

    Hawk 1000 Section 3 — Hardware Checkout 3.2.5 Moving The Actuator The actuator can be moved clockwise or counterclockwise by pressing either one of two red buttons located on the actuator (Figure 3-9). One red button moves the actuator shaft clockwise, and the other moves the actuator shaft counter-clockwise.
  • Page 30 Section 3 — Hardware Checkout Hawk 1000 3-12 Part No. 750-366...
  • Page 31 Options .........4-19 Configuration Summary ......4-23 www.cleaverbrooks.com...

  • Page 32: Introduction

    Figure 4-1. Firing Rate Screen A gray button on the HMI indicates that a password is required before user input is allowed. The Hawk 1000 employs three levels of security: Operator, Service, and Factory. Pressing a gray pushbutton will display the login entry window.

  • Page 33: Boiler Overview

    Hawk 1000 Section 4 — System Configuration Figure 4-2. Main Menu (all possible screens) Figure 4-3. Main Menu (initial startup) 4.3 Boiler Overview The Boiler Overview display (Figure 4-4) serves as the main point of interface for the operator. The primary purpose of the display is to monitor the current status of the boiler.

  • Page 34: System Configuration

    Section 4 — System Configuration Hawk 1000 Flextube Firetube Model 4/5 Figure 4-4. Boiler Overview 4.4 System Configuration The first step in commissioning t h e b o i l e r is to configure the control system options. On the M a i n Screen press <System Config >.
  • Page 35 Hawk 1000 Section 4 — System Configuration Figure 4-6. Warning 2 Press <Next> to continue. The following items are configurable when in system configuration: • Boiler Media Steam or Hot Water • Boiler Type - Firetube, Flextube or M4/M5 boiler •...

  • Page 36: Boiler Type And Media

    Section 4 — System Configuration Hawk 1000 Note that if a configuration setting is marked with an asterisk and the setting is changed the Combustion Curves will be erased. Caution If System Configuration is entered with the boiler running, a safety shutdown will occur.
  • Page 37 Hawk 1000 Section 4 — System Configuration Pressing <User> or <Password> will bring up an alphanumeric keypad. Use this (or the HMI hardware keypad) to enter your user name and password. A USB keyboard may also be used. Type the password (user name) followed by the Enter key.
  • Page 38 Section 4 — System Configuration Hawk 1000 Figure 4-8. System configuration In this example, “Firetube” is selected as the boiler type. After selecting the boiler media (steam or hot water) additional screen buttons will become available. Selecting “Steam” will bring up buttons for steam transmitter span, safety valve setpoint, and NOx level.
  • Page 39 Hawk 1000 Section 4 — System Configuration If a valid user name and password are entered, the operator will be allowed to change data. The current user login status can be seen in the top right corner of each screen.
  • Page 40 Section 4 — System Configuration Hawk 1000 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 . Warning The safety valve setting is critical to the proper operation of the boiler.

  • Page 41: Fuel Configuration

    Hawk 1000 Section 4 — System Configuration 4.4.2 Fuel Configuration Figure 4-10. Fuel configuration Number of Fuels Enter the Number of Fuels for this application. Acceptable values are either 1 or 2. High/Low control method MUST be fuel 2. Fuel 1/Fuel 2 Type...

  • Page 42: Flame Safeguard

    Select the type of Flame Safeguard used for the specific job. The CB780E and CB120E are the two selections available on the Hawk 1000 If CB120E is selected the Revert to Pilot Option is available (not available on the CB780E).

  • Page 43: Analog Inputs

    Hawk 1000 Section 4 — System Configuration Caution Revert to Pilot modes are to be determined in the field after careful analysis of the load conditions that necessitate the use of these mode of operation. Care should be taken to avoid unnecessary recycling and damage to the boiler equipment.
  • Page 44 Section 4 — System Configuration Hawk 1000 Figure 4-13. Analog Inputs (hot water) Analog Input I:2.3 For Steam systems Analog Input I:2.3 can be selected as None, Water Level, Remote Modulation, or Remote Set Point. If Water Level is selected it is mandatory that the Level Master is the sensor used to measure the water level.

  • Page 45: Remote Modulation/Remote Set Point

    Hawk 1000 Section 4 — System Configuration 4.4.5 Remote Modulation/Remote Set Point Signals for Remote Modulation or Remote Setpoint can be provided by either an analog input signal or written directly into the PLC by communications (Ethernet). Figure 4-14. Remote Mod/Setpoint by Communications Remote Modulation by Analog Input This configures the Boiler Controller to receive a remote 4-20mA signal on input I:2.3 to control the firing...
  • Page 46 Section 4 — System Configuration Hawk 1000 Figure 4-15. Remote Modulation signal select Remote Modulation by Communications This configures the Boiler Controller to receive a Remote Modulation signal directly by Communications (Ethernet). Modulation units range from 0-100%. Communication integrity is determined by a Communication Heartbeat signal between the Control System and the Building Management System.

  • Page 47: Actuator Selection

    Hawk 1000 Section 4 — System Configuration Communications failure is detected, an alarm message “Remote Communications Failed” is displayed on the HMI and Setpoint reverts back to the LOCAL setting on the HMI Warning Remote Set Point control should not be used on certain Low Emission boiler systems.

  • Page 48: Variable Frequency Drive

    Section 4 — System Configuration Hawk 1000 The Fuel 2 Actuator 2 should be selected as “Yes” if it is present on this system. This actuator is only available for parallel positioning control. Figure 4-16. Actuator selection 4.4.7 Variable Frequency Drive VFD Type Select the appropriate VFD Type for this specific job.

  • Page 49: Options

    Hawk 1000 Section 4 — System Configuration Figure 4-17. VFD screen Variable Frequency Drive for Combustion Air Fan Motor Variable frequency drives (VFDs) offer many benefits to reduce energy costs and extend the life of mechanical equipment. The optional Variable Frequency Drive (VFD; see Figure 2-7) controls the speed of the combustion air fan motor for the purposes of improving boiler efficiency and reducing electrical energy consumption.
  • Page 50 Hawk 1000 O2 Trim 02 trim control is an integral part of the HAWK 1000 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 (CB) and also allows for adjustment of PID tuning.
  • Page 51 Hawk 1000 Section 4 — System Configuration Overview - Hot Standby Force Hot Standby Figure 4-20. Hot Standby Outdoor Temperature Reset (Hot Water units only) With 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 A na lo g I n pu t 2 .
  • Page 52 Section 4 — System Configuration Hawk 1000 Boiler Information The customer name, boiler ID, and boiler serial number and can be entered. This information is displayed on the System Information Screen. To enter this information, press the text display button beneath the description.

  • Page 53: Configuration Summary

    To complete system configuration, press the <Confirm Options> pushbutton on the Options Summary Screen. The Configuration selections may be changed after the HAWK 1000 is installed. However, for many of the options, additional hardware is required to make the function work. Please refer to the parts section for the required hardware.
  • Page 54 Section 4 — System Configuration Hawk 1000 4-24 Part No. 750-366...
  • Page 55 Thermal Shock Routine ........... . . 5-18 www.cleaverbrooks.com...

  • Page 56: Commissioning The Actuators

    Section 5 — Commissioning Hawk 1000 5.1 Commissioning the Actuators When system configuration is complete, the <Calibrate Actuators> button will be available on the Main screen and will indicate “Required”. Figure 5-1. Actuator calibration required Press <Calibrate Actuators> for the Actuator Commissioning screen, where air, fuel, and FGR actuators can be individually selected for commissioning.
  • Page 57 Hawk 1000 Section 5 — Commissioning Figure 5-3. Actuator rotation The default direction of rotation is counterclockwise for air and all fuels, and clockwise for FGR. This screen also indicates the actuator torque rating (read via Modbus by the PLC).

  • Page 58: Setting Combustion - Parallel Positioning

    Section 5 — Commissioning Hawk 1000 Save Data Invalid Data Figure 5-5. Verify actuator calibration 5.2 Setting Combustion - Parallel Positioning When actuators for the currently selected fuel have been calibrated, the <Set Combustion> button will be available on the Main screen. To begin the procedure, press <Set Combustion> and observe the warning that follows.

  • Page 59: Store Purge

    Hawk 1000 Section 5 — Commissioning 5.2.1 Store Purge The first step is to store the Purge position. A help screen is available to guide the user through storing the Purge (and Lightoff) positions: Figure 5-7. Purge/Lightoff help For a valid Purge position the air actuator must be greater than 80% open. To position the actuators in setting combustion, first press the button for the desired actuator on the Combustion Setup screen.

  • Page 60: Store Lightoff

    Section 5 — Commissioning Hawk 1000 Figure 5-9. Adjust actuator When purge position is set, press <Store Purge>. When prompted with “Store Current Values?”, press <Store Purge> again to confirm or <Cancel> to re-adjust. Figure 5-10. Store Purge Note: If a VFD is present, the VFD purge value is automatically set at 100%.

  • Page 61: Curve Setup

    Hawk 1000 Section 5 — Commissioning Figure 5-11. Store Lightoff 5.2.3 Curve Setup A help screen is available to guide the user through the steps of setting the combustion curve: Figure 5-12. Combustion setup help To set the combustion curve, the burner must be on. If all conditions to start the boiler have been met, the <Burner Start>...

  • Page 62: Setting Combustion - Single Point Positioning

    Section 5 — Commissioning Hawk 1000 Figure 5-13. Combustion curve complete 5.3 Setting Combustion - Single Point Positioning 5.3.1 VFD or O2 Trim If VFD or O2 Trim is selected, combustion setup is identical to parallel positioning, with the exception that only the air actuator will be active.

  • Page 63: Firing Rate Screen

    Hawk 1000 Section 5 — Commissioning When steam pressure is greater than the low fire point, the firing rate will go to 0%. When steam pressure is less than the high fire point, the firing rate will go to 100%.
  • Page 64 Section 5 — Commissioning Hawk 1000 Figure 5-17. In the event of a bad remote signal, an alarm message will appear on the screen and the control will revert to Local/Auto mode. The <Adjust Gains> button accesses the system PID tuning. Default values are: P=5, I=5, D=0.

  • Page 65: Alarms And Limits

    Hawk 1000 Section 5 — Commissioning Figure 5-20. View Actuators The <Manipulate Actuators> button allows the actuators to travel through 0-100% of firing rate to verify all actuators are positioning correctly at the current firing rate. To use this feature, the Burner Switch must be OFF and firing rate must be in MANUAL mode.

  • Page 66: Mod. Rate Limiter, Max. O2 Correct, Remote Shutdown By Comms

    Section 5 — Commissioning Hawk 1000 5.6.3 Mod. Rate Limiter, Max. O2 Correct, Remote Shutdown by Comms. Modulation rate limiting increases/decreases the rate of change of firing rate output. The value entered is the number of seconds the control output will take to go between 0-100%...

  • Page 67: Setpoints

    Hawk 1000 Section 5 — Commissioning 5.7 Setpoints 5.7.1 Operating Setpoint Figure 5-23. Operating Setpoint Steam Pressure (Water Temperature) setpoint and on/off differential are set here. If dual setpoint is selected, the Operating Setpoint 2 can be entered from the HMI but the ON/OFF points are calculated using the same dP/dT as Setpoint 1.

  • Page 68: Revert To Pilot (Cb 120E Only)

    Section 5 — Commissioning Hawk 1000 OUTDOOR RESET CURVE Set point is linear in relation to the outdoor temperature. Range for outdoor temperature transmitter is 4 ma = -50 deg F, 20 ma = 900 deg F. In this example:...

  • Page 69: O2 Trim

    Hawk 1000 Section 5 — Commissioning Revert to Pilot Pressure must be greater than the boiler operating Setpoint or boiler On Point, whichever is greater. Figure 5-26. Revert to Pilot Initiated by digital input If ‘Initiate by digital input’ is selected, the above screen will not be shown; Revert to Pilot will be initiated when digital input I:5.7 ALFCO is OFF.

  • Page 70: Drive Data

    Section 5 — Commissioning Hawk 1000 5.9 Drive Data If a VFD is present, <Drive Data> will display a read-only screen showing drive output and feedback, Low/ High/Lightoff settings, and current running frequency. 5.10 Ethernet Configuration Multiple boilers on the same Ethernet network require unique IP addresses. To change a boiler’s configuration, press the desired field in the “Set New Ethernet Configuration”...

  • Page 71: Two Boiler Lead Lag

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

  • Page 72: Thermal Shock Routine

    Section 5 — Commissioning Hawk 1000 5.12 Thermal Shock Routine Steam boilers Thermal shock protection is activated when actual water temperature is below 60% of the steam saturation temperature at set point. Maximum limit for CV for PID is based on water temperature and is determined by function.
  • Page 73 PLC Status..........6-4 www.cleaverbrooks.com...

  • Page 74: System Monitoring And Diagnostics

    6.1 System Monitoring and Diagnostics 6.1.1 Boiler Overview The Hawk 1000 has a number of features for monitoring system performance and diagnosing problems. The Boiler Overview screen shows the primary operating details of the boiler and is accessible from the Main screen.

  • Page 75: System Information

    External Interlock - Feedback input from external interlock. When there is a load demand, and the burner switch and limits are closed, the HAWK 1000 has isolated contacts (2.5A @ 125VAC) for output to an external interlock device (e.g. fresh air damper, circulating pump). The boiler will start once the external interlock is proven.

  • Page 76: Plc Status

    Section 6 — Diagnostics and Troubleshooting Hawk 1000 6.1.5 Diagnostic Screens Press <Diagnostic> on the Main screen for the diagnostic screen menu. Select an item from the menu to show a detailed view of the corresponding program logic. Items in green are TRUE and those in white are FALSE.
  • Page 77 Hawk 1000 Section 6 — Diagnostics and Troubleshooting Table 1: PLC Status LEDs (Continued) 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.
  • Page 78 Section 6 — Diagnostics and Troubleshooting Hawk 1000 Part No. 750-366...
  • Page 79 Section 7 Parts PLC, I/O, HMI Part Number Description 880-06082-000 Hawk 1000 Kit - must be ordered as complete kit only 833-10039-000 PLC Processor 833-10040-000 4 Inch PV+ Compact Touch Screen with (118-04514-000 label included) 833-02842-000 Digital Input Module 833-02872-000...
  • Page 80 Section 7 — Parts Hawk 1000 MISC. Part Number Description 833-02835-000 1769-IF4 Analog Current Input Module (req. w/ O2 Trim, VFD, or Combustion Air Temp option) 833-10116-000 9300-ENA Ethernet Appliance Router 817-05166-000 Temperature Sensor, 8" Probe, -50-900 Deg F 833-09181-000...
  • Page 81 Hawk 1000 Section 7 — Parts STEAM TRANSMITTERS Part Number Description 817-04866-000 E&H PMC131-A22F1Q4H 817-00001-000 E&H PMC131-A22F1Q4N 817-04867-000 E&H PMC131-A22F1Q4R 817-04868-000 E&H PMC131-A22F1Q4S 817-04869-000 E&H PMC131-A22F1Q4T Steam Transmitters (Optional) 817-04873-000 PMP51-1CQW9/0 (includes Isolation Valve) 817-00002-000 PMP51-1R5E5/0 (includes Isolation Valve) 817-04874-000...
  • Page 82 Section 7 — Parts Hawk 1000 Part No. 750-366...

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