Hawk 4500 - Cleaver-Brookscleaverbrooks.com/docs/manuals/CB750-427-Hawk4500.pdf · 2019-06-07 · Cleaver-Brooks HAWK 4500 Boiler Control Operation Manual Manual Part No. 750-427

750-42703/2019

Hawk 4500Boiler 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 4500 Boiler Control

Operation Manual

Manual Part No. 750-42703/2019

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

Printed in U.S.A.

CONTENTSSection 1

IntroductionIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2Hawk 4500 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3Burner Management Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3PLC Rack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

Input/Output List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5Human-Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8Steam Systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8Hot Water Systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Safety Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

Section 2Hardware Setup

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

Modbus Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7Setting The Modbus Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8Power/ Communications LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9Moving the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Section 3System Configuration

Logging In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5Configuration Screen #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Boiler Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7Fuel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Configuration Screen #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10Actuator Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10Full Metering Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

Configuration Screen #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12Pressure Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13Atomizing Media Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13Air PreHeater Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

Configuration Screen #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14Auto Recycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14Variable Frequency Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

Configuration Screen #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17Feedwater Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

Configuration Screen #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19CB Master Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19Remote Modulation/Remote Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19Dual Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Configuration Screen #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

Configuration Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22VFD Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23Email Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

SMTP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29

Text/Email Contact List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29Change the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30PanelView Plus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Change the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31Installing a PV+ Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32Viewing the PV+ Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Section 4Commissioning

Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Setting Combustion - Full Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Full Metering Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Combustion Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Store Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Store Lightoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Curve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Setting Combustion - Parallel Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Store Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Store Lightoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Curve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18No VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Combustion Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Remote Setpoint/Remote Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Dual Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Tuning and Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21Alarms and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Alarms and Limits Screen 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23Alarms and Limits Screen 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25Operating Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Revert to Pilot (CB 120E only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26VFD Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27PLC Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27Thermal Shock Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Section 5Diagnostics and Troubleshooting

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

Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7PLC Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Fault List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Section 6Parts

www.cleaverbrooks.com

Section 1Introduction

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Hawk 4500 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Burner Management Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3PLC Rack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Input/Output List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Human-Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8Steam Systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8Hot Water Systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Safety Provisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Section 1 — Introduction Hawk 4500

1.1 IntroductionThe Cleaver-Brooks HAWK 4500 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 4500 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.

The HAWK 4500 provides boiler firing rate control to maintain steam pressure (or hot water supplytemperature) at set point. Final control element(s) are controlled via Modbus communications network toinsure that the optimum fuel/ air ratio is maintained throughout the firing range.

The Hawk 4500 supports three fuel types. Fuel/air ratio is controlled using either parallel positioning or single-point control method.

The Hawk 4500 can be monitored by Building/ Plant Automation Systems via an optional CB ProtoNodeprotocol translator. Ethernet / Internet communication also enables remote monitoring of the Hawk 4500Boiler Control System (additional software and/or hardware required).

The HAWK 4500 may be used on most types of industrial watertube boilers. In addition to installation on newboilers, the HAWK 4500 can be added as a retrofit to existing boilers. Call your local authorized Cleaver-Brooks representative for details.

Consult the following Cleaver-Brooks manuals for supplementary operating and maintenance information:

ProtoNode Gateway communication interface - 750-361CB120E Burner Control - 750-264CB780E Burner Control - 750-234Variable Frequency Drives - 750-198O2 Trim - 750-224Draft Control - 750-221Economizers - 750-266

1-2 Part No. 750-427

Hawk 4500 Section 1 — Introduction

1.2 Hawk 4500 System Features• Automatic sequencing of the boiler through standby, pre-purge, pilot flame establishing period, main flame establishing period,

run and post purge.• Flame proving and lockout on flame failure during pilot flame proving, main flame proving, or run.• Low fire damper/valve position for flame ignition trials.• Single Point Positioning, Parallel Positioning or Full Metering combustion control for air and maximum 2 fuels• Optional Variable Frequency Drive on combustion air fan blower motor• Optional O2 Trim• Optional Integrated Draft Control (requires external damper, low draft switch and draft transmitter - CB damper assembly

includes these items as a standard).• Thermal Shock Protection with mud drum temperature monitoring (optional) and set point. • 10 inch touch screen graphical operator interface and monitor.• HMI screens published via integrated web server in HMI.• Ethernet communications to Variable Frequency Drive (if used)• E-mail of boiler alarms.• Building/Plant Automation System interface (may require protocol translator based on specific protocol required - Hawk 4500 is

compatible with CB ProtoNode protocol translator).• High Stack Flue Gas Temperature Monitoring, Cut-Off and Alarm.• Tamper resistant control logic and password protection.• Dual Set Point (Night/Day Set Back) Capabilities.• Combustion Air Temperature (optional).• Lower drum Water Temperature (optional).• Boiler Drum Water Level Indication.• Outdoor Reset for Hot Water Boilers (optional).• Return Hot Water Temperature (optional)• Remote Modulation.• Remote Firing Rate Set Point control (optional and only if Remote Modulation is not used.)• Assured Low Fire Cut-Off (ALFCO; used to remote stop/start the burner).• Local drum or steam header control.• Hot Stand By and Force Hot Standby on single boiler.• PLC based expanded diagnostics with 1 auxiliary discrete (digital) input.• Alarm Silencer via touch screen HMI

1.3 Burner Management ControlThe Hawk 4500 utilizes either the CB780E or CB120E Burner Control

• Communicates with the PLC via Modbus• Burner Control Status, Faults and Diagnostics displayed on HMI or panel mounted burner control

Flame condition monitoring using either IR or UV Flame Scanner

Figure 1-1. Burner Management Control

CB780E CB120E

Part No. 750-427 1-3


123456789111

1.4 PLC Rack ComponentsThe principal components of the HAWK 4500 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 4500 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.

The 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.

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 4500 controls will not function unless all devices are properly installed and configured.

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 4500 PLC converts this current value to a range in engineering units. Example:

Steam Pressure (0-150 PSI)

Figure 1-2. Hawk 4500 PLC Rack

1 2 3 4 5 6 7 8 9 10 1111 12

. (Slot 0) - PLC L36ERM

. (Slot 1) - Modbus Module SM2

. (Slot 2) - Digital Inputs

. (Slot 3) - Digital Outputs

. Power Supply

. (Slot 4) - Analog Inputs

. (Slot 5) - Analog Outputs

. (Slot 6) - Analog Inputs

. (Slot 7) - Digital Inputs0. (Slot 8) - Analog Inputs1. (Slot 9) - Analog Outputs2. (Slot 10) - Analog Inputs

1-4 Part No. 750-427


1.4.1 Input/Output List

Slot 0Processor

Slot 1Modbus Card

Slot 2 - Digital Inputs Slot 3 - Digital Outputs Power Supply

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 Header or 2 BLL Press (Water Temp)

I2/4 VFD Bypass O3/4 Revert to Pilot I4/4 Air Damper Pos Feedback

I2/5 Ready To Start/ Limits Closed

O3/5 Prove High Fire I4/5 Fuel 1 Pos Feedback

I2/6 Ext. Device Start Interlock (FAD)

O3/6 Alarm Output I4/6 Fuel 2 Pos Feedback

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

O3/7 Boiler Ready (L-L) I4/7 FGR Pos Feedback

I2/8 Pilot TerminalI2/9 Main Fuel Terminal

I2/10 Fuel 1 SelectedI2/11 Fuel 2 Selected

I2/12 FSG Alarm TerminalI2/13 LWCO ShutdownI2/14 Rem. Mod/SP, DSP,

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

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

O5/0 VSD Control Output I6/0 Stack Temp. (before Econ.) I7/0 Stack Damper Open Switch I8/0 Analog 0/Atom Air Diff Press

O5/1 Control Output LL I6/1 Comb. Air Temperature I7/1 Furnace Pressure High High I8/1 Analog 1/Main Flame ScannerO5/2 Draft Control I6/2 Water Shell (ST) Outdoor Temp

(HW)I7/2 Force to Low Fire I8/2 Analog 2/Aux Flame Scanner

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

O5/4 Atomizing Steam Control Valve

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

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

O5/5 Air Preheater Steam Control Valve

I6/5 Economizer Temp Water IN (ST) I7/5 Low Gas Pressure/Low Oil Temp - F1-F2-F3

I8/5 Analog 5/Windbox Damper Pos Feedback

I6/6 VFD Feedback I7/6 High Gas Pressure/High Oil Temp/High - F1-F2-F3

I8/6 Analog 6/Fuel 1 Stab Gas Damper Pos Feedback

I6/7 Draft Signal I7/7 Low Oil Pressure I8/7 Analog 7/Remote Modulation/Setpoint

I7/8 Atomizing Air Pressure Cold StartI7/9 Oil Drawer SwitchI7/10 Atomizing Air Pressure LowI7/11 Combustion Air Pressure LowI7/12 Instrument Air Low Low PressureI7/13 Stack Damper High Pressure Switch I7/14 Low Water AlarmI7/15 Auxiliary #1/Flame Scanner(s) Fault

Slot 9 - Analog Output Slot 10 - Analog InputAddress Name Address Name

O9/0 Air Damper I10/0 Air FlowO9/1 Fuel 1 Control Valve I10/1 Fuel 1 FlowO9/2 Fuel 2 Control Valve I10/2 Fuel 2 FlowO9/3 FGR Damper I10/3 FGR FlowO9/4 Windbox Damper I10/4 Natural Gas TemperatureO9/5 Fuel 1 Stab Gas Control

ValveI10/5 Pegging Steam Flow

O9/6 I10/6 Oil TemperatureO9/7 I10/7

Part No. 750-427 1-5


1.5 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.

Figure 1-3. Hawk 4500 HMI

Figure 1-4. Hawk 4500 HMI connections

1 1

USB

EtherNet120VAC power

NOT USED

1-6 Part No. 750-427


1.6 Communications1.6.1 ModbusModbus is an open serial protocol used by the HAWK 4500 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 4500 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.

1.6.2 EthernetThe HAWK 4500 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

1.6.3 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 1-5. SM2 Modbus Module

Part No. 750-427 1-7


Figure 1-6. L36ERM PLC Communication Ports

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

2.7.1 Steam Systems:Steam Pressure is the primary sensor input to the HAWK 4500 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 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.

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 YesComb. Air Temperature ST & HW Yes

PORT 1

PORT 2ETHERNET

BOTTOM OF CONTROLLER

USB

1-8 Part No. 750-427


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

2.7.2 Hot Water Systems:Supply Temperature is the primary sensor input to the HAWK 4500 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.

1.8 Safety Provisions• 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

1.9 Environmental Specifications

Supply Voltage 120vac (+10%/-15%) 50 or 60 HzMaximum total connected load 2000 VAOperating temperature limits 32 to 130 deg FHumidity 85% RH continuous, non-condensingVibration 0.5G continuous vibration

Part No. 750-427 1-9


Section 2Hardware Setup

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

Modbus Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Setting The Modbus Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8Power/ Communications LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Moving the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Section 2 — Hardware Setup Hawk 4500

2.1 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.

2.1.1 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 2-1. DIN rail latches

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

Important!

2-2 Part No. 750-427

Hawk 4500 Section 2 — Hardware Setup

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

2.1.3 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).

2.1.4 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 2-3. SM2 module DIP switch setting

Part No. 750-427 2-3


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.

2-4 Part No. 750-427



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. 750-427 2-5


Press upper arrow key to exit.

2.1.5 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.

2.1.6 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

2-6 Part No. 750-427


2.2 Modbus Actuators2.2.1 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.

2.2.2 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 2-4. Actuator Wiring, Quick Plug

Part No. 750-427 2-7


Figure 2-5. Actuator wiring (hard wired)

2.2.3 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

2-8 Part No. 750-427


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.

2.2.4 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 2-6. 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. 750-427 2-9


2.2.5 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 2-7. 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)

2-10 Part No. 750-427


Section 3System Configuration

Logging In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5Configuration Screen #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Boiler Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Fuel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Configuration Screen #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Actuator Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Full Metering Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Configuration Screen #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12Pressure Transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Atomizing Media Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Air PreHeater Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

Configuration Screen #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Auto Recycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14Variable Frequency Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Configuration Screen #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17Feedwater Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

Configuration Screen #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19CB Master Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19Remote Modulation/Remote Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19Dual Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Configuration Screen #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21

Configuration Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22VFD Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23Email Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

SMTP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29Text/Email Contact List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29

Change the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30PanelView Plus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31

Change the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31Installing a PV+ Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32Viewing the PV+ Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38

Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39

Section 3 — System Configuration Hawk 4500

The Hawk 4500 is equipped with a 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

3.1 Logging InCertain actions on the HMI require a password before allowing user input. The Hawk 4500 employs three levels of security: Operator, Service, and Factory. When a password is required, the login entry window is displayed.

Figure 3-1. Login Window

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.

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

3-2 Part No. 750-427

Hawk 4500 Section 3 — System Configuration

3.2 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 3-2. Alphanumeric keypad

Part No. 750-427 3-3


Figure 3-4. Main Menu (initial startup)

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

3-4 Part No. 750-427


3.3 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 3-5. Boiler Overview screen (steam boiler)

3.4 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.

Figure 3-6. Warning

Part No. 750-427 3-5


The following items are configurable when in system configuration mode.

Configuration Screen 1:• Boiler Media (Steam or Hot Water)• Fuel Control Method (Parallel Positioning, Single Point, or Full Metering)• Safety Valve Setpoint (Steam)/Max Rated Temperature (HW)• NOx Level (PPM)• Number of Fuels (up to 3)• Fuel Type and Turndown for each fuel• Temp Transmitter Configuration• FGR (Yes/No)• 2nd fuel actuator (Yes/No) for each fuel• 2nd Air Actuator

Configuration Screen 2:• Actuator Type (Modbus, Analog, None) for Air, Fuel, FGR• FGR Purge Enable

Full Metering Configuration Screen 1 (Full Metering mode only)• Air Flow Temperature Compensation, Actuator Feedback Option

Full Metering Configuration Screen 2 (Full Metering mode only)• Air Flow Transmitter Configuration, Fuel 1 Flow Transmitter Configuration

Full Metering Configuration Screen 3 (Full Metering mode only)• Fuel 2 Flow Transmitter Configuration, FGR Flow Transmitter Configuration

Configuration Screen 3:• Pressure Transmitter Configuration• Atomizing Media Configuration• Air Preheat Configuration

Configuration Screen 4:• Flame Safeguard Select (CB780E or CB120E)• VFD Configuration• O2 Trim Configuration• Auto Recycle

Configuration Screen 5:• Combustion Air Temperature• Flame Scanner• Aux Analog Inputs• Draft Control• Feedwater Control Type (1, 2, or 3 element)• Mud Drum Temp Sensor

Configuration Screen 6:• Lead Lag Configuration• Remote Modulation/Remote Setpoint• Hot Standby• Dual Setpoint

Configuration Screen 7:• Customer and Boiler Identification

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

3-6 Part No. 750-427


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.

3.5 Configuration Screen #13.5.1 Boiler Media

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

! 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.

Figure 3-7. Configuration Screen #1

Part No. 750-427 3-7


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.

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.

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. 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:

! 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

Popup keypad Invalid entry

CURRENT VALUE

RANGE

3-8 Part No. 750-427


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 O 250 Deg F the Supply Temp Transmitter is set to 50-300 Deg F.

If the Max Rated Temperature > 250 Deg F the Supply Temp Transmitter is set to 50-500 Deg F.

NOx Level (PPM)

Enter the NOx Level for this specific job.

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

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

3.5.2 Fuel Configuration

Figure 3-8. Fuel configuration

Number of Fuels

Enter the number of fuels for this application (1 or 2).

Fuel Control Method

Select the type of combustion control method for this application.

Acceptable entries are Parallel Positioning, Single Point Positioning, or Full Metering.

Fuel Type

Select the Fuel type for each fuel for this application.

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

Part No. 750-427 3-9


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.

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.

3.6 Configuration Screen #2

3.6.1 Actuator Configuration

Air/Fan Inlet Actuator Type Select <Analog Actuator>, <Modbus Actuator>, or <No Actuator> as appropriate.

Air/Fan Outlet Actuator Type Select <Analog Actuator>, <Modbus Actuator>, or <No Actuator> as appropriate.

Fuel 1 Actuator 1(main fuel actuator)Select <Analog Actuator>, <Modbus Actuator>, or <No Actuator> as appropriate.

Fuel 1 Actuator 2 (secondary/stabilizer gas actuator)Select <Analog Actuator>, <Modbus Actuator>, or <No Actuator> as appropriate.

Fuel 2 Actuator 1Select <Analog Actuator>, <Modbus Actuator>, or <No Actuator> as appropriate.

FGR ActuatorSelect <Analog Actuator>, <Modbus Actuator>, or <No Actuator> as appropriate.

FGR PurgeSelect <Yes> or <No>.

3-10 Part No. 750-427



3.6.2 Full Metering Configuration

If Full Metering has been selected as the fuel control method, pressing <Next> from Config Screen #2 will bring up additional screens for full metering configuration.

Full Metering Options

Figure 3-10. Full Metering Options Configuration

Actuator position feedback may be optionally enabled with full metering selected. If <Yes> is selected, position feedback will be displayed on the Combustion Control screen.

Part No. 750-427 3-11


Flow Input Configuration

Figure 3-11. Full Metering Flow Input Configuration

Units, input range, and alarm points are configured here for air, fuel (up to 2 fuels), and FGR (if selected).

“Design Flow” represents the fuel flow in Engineering Units for the design capacity of the boiler. A valid entry is important here, as this value will be used in the combustion setup process to establish the flow target for each point in the combustion curve. A Design Flow Help screen is available, shown below.

When fuel configuration is complete, press <Next> to go to Configuration Screen #3.

Figure 3-12. Design Flow Help

3-12 Part No. 750-427



3.7.1 Pressure Transmitters

The Hawk 4500 can accept inputs from a steam header and/or drum pressure transmitter.

Select either <Drum Pressure Transmitter>, <Header Pressure Transmitter>, or both. If both are selected, choose one as the primary transmitter. In the event of transmitter failure, the second transmitter will operate as a backup.

Configure the 4-20mA span for the primary transmitter. If both transmitters are selected, the span on the secondary transmitter takes the same values.

3.7.2 Atomizing Media Control

Select <Yes> if using steam atomization. Steam Atomization will now be configurable in Combustion Control.

If <Atomizing Differential Pressure> is selected, the Atomize Media Control screen will now be accessible from the Main screen. On this screen:

• In Auto, with override off, the Trim function will adjust the output to try to maintain the DP Setpoint, which comes from the stored combustion curve. In manual, with override off, the output can be manipulated up or down using the increment/decrement buttons.

• If the main fuel is off, the output will be in override and forced to 50%, (no trim). The output is scaled based on the trim limit. For a trim limit of +/- 10% the 0-100% output will be scaled to 0.9 to 1.1 as a multiplier to the atomize valve setpoint.

• The No RTM (No Release to Modulate) limits apply when burner control is not released to modulate. The output limit is returned to 0-100% after release to modulate.

3.7.3 Air PreHeater Control

Select <Yes> if using an air preheater and an output is present at O5/5. The Air Preheater Control screen will be accessible from the Main screen.


Part No. 750-427 3-13



3.8.1 Flame Safeguard

Figure 3-15. FSG configuration

Select the type of Flame Safeguard used for the application.

The CB780E and CB120E are the two selections available for the Hawk 4500

3.8.2 Auto Recycle

If <No>, HMI Burner Start pushbutton must be engaged to restart boiler after a shutdown. If <Yes>, boiler will automatically recycle upon demand after a non-safety shutdown.

3.8.3 Variable Frequency Drives

The Hawk 4500 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.

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.


3-14 Part No. 750-427


VFD Bypass

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

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 3-16. 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.

3.8.4 O2 Trim

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 4500 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 3-17. O2 Trim

Part No. 750-427 3-15


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

High/Low O2 Shutdown

High/Low 02 Shutdown allow the boiler to be shutdown if O2 concentrations become too high or too low.

O2 Shutdown can be enabled or disabled b y toggling the appropriate button (on the System Configuration screen) between <Yes> and <No>.If enabled the High/Low O2 Shutdown Setpoint and High/Low O2 shutdown time delay can be adjusted on the Alarms and Limits screen.

Figure 3-18. Flue Gas O2 Control Screen

Figure 3-19. O2 Tuning & Trends

3-16 Part No. 750-427




Certain system inputs/outputs are configured on this screen.

• Economizer - Select <Yes> if using an economizer. Select <Economizer Water Temperature In [Out]> as appropriate. Requires input at I6/5 (temperature in) or I6/3 (temperature out).

• Combustion Air Temperature - Input I6/1. The Combustion Air Temp Sensor transmits a 4-20mA signal to the controller. The Combustion Air Temp signal is used in the boiler efficiency calculation, and is displayed on the Boiler Overview screen.

• Flame Scanner 1 - Inputs I8/1 (flame signal) and I7/14 (alarm)

• Flame Scanner 2 - Inputs I8/2 (flame signal) and I7/15 (alarm)

• Auxiliary Analog Inputs - Slot 8 Analog Input module

• Draft Control - Output O5/2, Input I6/7

• Mud Drum Temperature - Input I6/2

• Surface Thermocouple - used for shell temperature where a temperature probe is not available

3.9.1 Feedwater Control

Configuration Screen #5 also allows selection of feedwater control type (one, two, or three-element) and shows the inputs being used for the control method selected.

• One-element control requires a Level input at I4/1.• 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.

Part No. 750-427 3-17


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.

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.

PV

LT

SPOperatorsetpoint

CV

I4/1

O5/3

To feedwater valve

1-element level control

PIDCONTROL

Figure 3-21. 1-Element Control

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


3-18 Part No. 750-427




3.10.1 CB Master Lead Lag

If the boiler will be utilized in a Plant Master control system, select <CB Master Lead Lag> and select either <Hard Wired> or <Comms> according to the type of Plant Master connection. See the CB Plant Master manual for further information on Master Lead/Lag configuration and operation.

3.10.2 Remote Modulation/Remote Setpoint

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

4-20ma signal is wired to Slot 8 Input 7 of the PLC. With Remote Modulation selected, the signal is scaled from 0-100%, (4mA = Low Fire and 20mA = High Fire).

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.

Part No. 750-427 3-19


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

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.

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.

3-20 Part No. 750-427


3.10.3 Dual Set Point

Dual Set Point control - traditionally referred to as night setback - allows the Boiler Controller to easily switch from the primary set point (Set Point 1) to the setback set point (Set Point 2). Set Point 1 is the primary set point for the Controller and is the only set point available if the Dual Set Point option is disallowed (see below). Setback can be initiated manually (through the HMI on the Firing Rate screen) or remotely (by energizing an isolated contact input signal (120 VAC) on digital input 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).


3.11.1 Boiler Information

The 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.

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.

! 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.

Part No. 750-427 3-21



3.12 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.

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

The Configuration selections may be changed after the HAWK 4500 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.

3.13 VFD Ethernet ConfigurationIf a PowerFlex drive will be connected to the Hawk 4500, 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.

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.

3.Press

Figure 3-27. System Configuration Summary

Part No. 750-427 3-23


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

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).

a.PowerFlex400: Parameter 15

b.PowerFlex70/700: Parameter 16

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

3-24 Part No. 750-427


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 3-28. 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 3-29. Initial PF Drive configuration screen.

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.

Part No. 750-427 3-25


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 3-30. 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.

3-26 Part No. 750-427


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.

Part No. 750-427 3-27


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

3-28 Part No. 750-427


3.14 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.

3.14.1 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.

3.14.2 Text/Email Contact List

The 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 3-31. SMTP Configuration (example)

Part No. 750-427 3-29


3.15 Change the Date and TimeSelect <Update Date/Time> on the Main screen.

Figure 3-32. Email List

Figure 3-33. Update Date and Time

3-30 Part No. 750-427


3.16 PanelView Plus SetupThe PanelView Plus 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.

3.16.1 Change the Date and Time

(Date and time settings can also be changed within the Hawk HMI, without entering PanelView setup, by going to the Update Date/Time screen as shown in 3.15 above).

Select 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.

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.

Figure 3-34. Date Settings

Figure 3-35.

Part No. 750-427 3-31


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

3.16.2 Installing a PV+ Program

The 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. Rockwell Software RSViewME Runtime Filename.mer (example: 98500671_xxx.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].

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 3-36.

3-32 Part No. 750-427


Figure 3-37.

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

Figure 3-38.

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

Part No. 750-427 3-33


[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].

Figure 3-39.

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].

3-34 Part No. 750-427


Figure 3-40.

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 3-41.

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 6

Part No. 750-427 3-35


192.168.1.127 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].

Figure 3-42.

III. SETTING RSLINX ENTERPRISE ETHERNET 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].

3-36 Part No. 750-427


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 Enter35.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]

Part No. 750-427 3-37


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

3.16.3 Viewing the PV+ Firmware

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

Figure 3-43. PV+Firmware

3-38 Part No. 750-427


3.17 Remote MonitoringThe PanelView Plus 7 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 7 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 3-44. Remote Monitoring

Part No. 750-427 3-39


Section 4Commissioning

Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Setting Combustion - Full Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Full Metering Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Combustion Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Store Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Store Lightoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Curve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Setting Combustion - Parallel Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Store Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Store Lightoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Curve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18No VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Combustion Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Remote Setpoint/Remote Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Dual Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Tuning and Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21Alarms and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Alarms and Limits Screen 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23Alarms and Limits Screen 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25Operating Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Revert to Pilot (CB 120E only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26VFD Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27PLC Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27Thermal Shock Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Section 4 — Commissioning Hawk 4500

4.1 Commissioning the ActuatorsWhen system configuration is complete, the <Calibrate Actuators> button will be available on the Main screen.

Figure 4-1. 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 4-2. 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).

Figure 4-3. 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).

Actuator Commissioning Screen Warning

4-2 Part No. 750-427

Hawk 4500 Section 4 — Commissioning

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 4-4. 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 feedback is given in units of degrees x 10 (or in mA if analog signal).

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.

Figure 4-5. 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.

Invalid Data Save Data

Part No. 750-427 4-3


4.2 Setting Combustion - Full Metering4.2.1 Full Metering MenuThe Full Metering menu provides access to data that will be useful in setting the combustion curves.

Oxygen Curve

For easier combustion tuning, an Oxygen Level setpoint curve is available for reference. There is a specific curve for each fuel.

Press <Edit Curve> to access the setpoint values.

Only the Y values can be changed; X values are based on the fuel flow target curve and can not be changed by the user.

A default curve is loaded when entering a new profile.

Figure 4-6. Full Metering Menu

Figure 4-7. Oxygen Curves

Figure 4-8. Edit Oxygen Curve (Fuel 1)

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Air/Fuel Deviation Setpoint

In a Full Metering combustion system, the Air/Fuel deviation is an important safety parameter. The deviation limit is a function of fuel flow. There is a specific curve for each fuel.

Although not recommended, the air/fuel deviation setpoint values can be edited by pressing <Edit Curve>

Air Flow Control

Air Flow Manual/Auto control is accessed from this screen. The default mode is AUTO.

Press <Tuning & Trend> to access a trend chart and the loop tuning parameters.

Figure 4-9. Air/Fuel Deviation Figure 4-10. Edit Air/Fuel Deviation Curve

Figure 4-11. Air Flow Control Figure 4-12. Air Flow Tuning & Trends

Part No. 750-427 4-5


Fuel Flow Control

Fuel Flow Manual/Auto control is accessed from this screen. The default mode is AUTO.

Press <Tuning & Trend> to access a trend chart and the loop tuning parameters.

SAMA Diagram

This screen shows a SAMA-format schematic representation of the Hawk 4500 control strategy.

This screen is used to access the Output Characterizers and also allows users to visualize the Double Cross-Limiting function; for more on both features see below.

Double Cross-Limiting

The double cross limiting system limits deviation between air and fuel. It includes two set point limiting devices: The low signal selector (K1) on the air side and the high signal selector (K4) on the fuel side. These

Figure 4-13. Fuel Flow Control Figure 4-14. Fuel Flow Tuning & Trends

Figure 4-15. SAMA Diagram Screen

DOUBLECROSS-LIMITING

OUTPUTCHARACTERIZER

4-6 Part No. 750-427


signal selectors will constrain the fuel and the air set point value within a determined deviation (K4 and K1) of the air flow and fuel flow value respectively.

On a small firing rate (less than 1%) change, the setpoint will be directly transmitted to the air flow and fuel flow controllers for fast reaction. On a greater change, the double cross limiting will perform the following actions:

Boiler demand increasing:

The high signal selector (K2) provides the remote set point to the air flow controller, and the low signal selector (K1) blocks the firing rate demand signal from the fuel flow. Air flow immediately starts increasing as the boiler demand signal increases. The low signal selector (K3) couples the increasing air flow signal to the fuel flow controller to increase fuel flow. This air flow increases before fuel flow increases.

Boiler demand decreasing:

The low signal selector (K3) provides the remote set point to the fuel flow controller. Fuel flow immediately starts decreasing as the boiler demand signal decreases, and the high signal selector (K4) blocks the firing rate demand signal from the air flow controller. The high signal selector (K2) couples the decreasing fuel flow signal to the air flow controller to decrease the air flow. Again, fuel flow decreases before air flow decreases.

The following parameters are used in double cross limiting:

K1 is the air to fuel deviation limit (function of K5 and K6)

K2 is the air demand bias and is set to 1%.

K3 is the fuel demand bias and is set to 1%.

K4 is the fuel to air deviation limit (function of K5 and K6).

K5 is the absolute deviation trip setpoint and is a function of the fuel flow. The combustion control system is more permissive to deviation at low load.

K6 is the deviation trip safety factor and is generally set to 2%.

Analog Output Characterization

While a linear output response is appropriate for most applications, it is possible to adjust the output to a curvilinear relationship. A help screen is available to explain the characterizer setup process.

From the SAMA screen, press on the desired characterizer to access the configuration screen.

CHARACTERIZER

Part No. 750-427 4-7


4.2.2 Combustion TuningWhen actuators for the currently selected fuel have been calibrated, the <Set Combustion> button will be available on the Main screen. When ready for burner tuning, press <Set Combustion> and observe the warning that follows.

Figure 4-18. 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.

Figure 4-16. Output Characterizer Tuning Figure 4-17. Characterization Help Screen

Important!It is required to populate the curves before the burner can be released for automatic control. In most applications, linear curves can be used, in which case the curves can be populated prior to tuning combustion.

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4.2.3 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:

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 4-19. 2nd Warning

Figure 4-20. Purge/Lightoff Help

Part No. 750-427 4-9


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.

Note: If a VFD is present, the VFD purge value must be set above 80%.

Figure 4-21. Combustion Setup

Figure 4-22. Store Purge

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4.2.4 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 4-23. Combustion Setup - Purge value stored

Figure 4-24. Store Lightoff

Figure 4-25. Combustion Setup - Lightoff stored

Part No. 750-427 4-11


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

To set the combustion curve, the burner must be on. The actuators can now be positioned for the first point.

• 10 points must be stored• Points can not be skipped• Values for Air Flow and Fuel Flow

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 <PrevPoint> is pushed.

Figure 4-26. Full Metering Curve Setup Help

Figure 4-27. Curve Complete

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4.3 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 4-28. 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.

4.3.1 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:

Main Screen

Warning

Figure 4-29. 2nd Warning

Part No. 750-427 4-13


Figure 4-30. 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 4-31. 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.

4-14 Part No. 750-427


Figure 4-32. Store Purge

4.3.2 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.

Note: If a VFD is present, the VFD purge value must be set above 80%.

Figure 4-33. Combustion Setup - Purge value stored

Part No. 750-427 4-15


Figure 4-34. Store Lightoff

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

Figure 4-35. Combustion Setup - Lightoff stored

4-16 Part No. 750-427


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

• 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 4-37. Combustion curve complete

Figure 4-36. Combustion setup help

Part No. 750-427 4-17


4.4 Setting Combustion - Single Point Positioning

4.4.1 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.

4.4.2 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.

4.5 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.

4.6 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.

Figure 4-38. Combustion Control screen

4-18 Part No. 750-427


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.

4.6.1 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 4-39. Remote Modulation / Remote Setpoint

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

Part No. 750-427 4-19


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.

4.6.2 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.

Figure 4-40. Remote bad signal

Figure 4-41. Rem Mod/Rem SP Help

4-20 Part No. 750-427


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

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.

Screen Trended variable (press <Tuning & Trend> to view)Firing Rate Steam Pressure (Water Temperature)Flue Gas O2 Control Stack O2%Feedwater Level Control Feedwater LevelAtomize Media Control Steam/Oil Differential PressureAir Preheater Control Combustion Air Temperature

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 4-42. Dual Setpoint

Figure 4-43. Tuning & Trend Screen (steam pressure)

Part No. 750-427 4-21


For flow inputs, the Hawk 4500 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 4-44. Analog Inputs screen

Figure 4-45. Analog Input Configuration

4-22 Part No. 750-427


4.8 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:

4.8.1 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 4500. 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 4500 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.

Figure 4-46. Alarms and Limits screen 1

Part No. 750-427 4-23


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.

4.8.2 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).

Figure 4-47. Alarms and Limits screen 2

4-24 Part No. 750-427


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

4.9.1 Operating Setpoint

Figure 4-48. Operating Setpoint

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

Set Point = steam pressure (water temperature) operating setpoint

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

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

4.10 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 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]

Part No. 750-427 4-25


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

Figure 4-49. 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.

4.11 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 4-50. O2 Trim

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.

4-26 Part No. 750-427


4.12 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.

4.13 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 4-52. Ethernet Configuration

After setting a new Ethernet configuration, communication between the HMI and PLC will be lost and must be reestablished from the HMI. The IP address entered in PLC Ethernet Configuration must match the PLC address setting in PV+ Configuration.

Figure 4-51. VFD Data

Part No. 750-427 4-27


To change the PanelView PLC IP address setting:

Press <PV+ Config>.

Go to Networks and Communications>RSLinx Enterprise Communications.

For more information, see Section 3.16 - PanelView Plus Setup.

4.14 Thermal Shock RoutineSteam Systems with Mud Drum Temperature:

Thermal shock protection is based upon the mud drum temperature. If the fuel valve is off and the mud drum temperature is below the thermal shock release setpoint, then thermal shock protection will be activated.

Thermal Shock is not released until the mud drum temperature is above the thermal shock release setpoint.

The maximum setting of the thermal shock release setpoint is 80% of the calculated saturation temperature setpoint. The calculated saturation temperature setpoint is calculated based upon the steam setpoint.

Steam Systems without Mud Drum Temperature:

Thermal shock protection is based on steam pressure. If the fuel valve is off and the steam pressure is below the thermal shock release setpoint, then thermal shock protection will be activated.

Thermal Shock is not released until the steam pressure is above the thermal shock release setpoint.

The maximum setting of the thermal shock release setpoint is 80% of the steam setpoint.

4-28 Part No. 750-427


Section 5Diagnostics and Troubleshooting

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

Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7PLC Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8Fault List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Section 5 — Diagnostics and Troubleshooting Hawk 4500

5.1 System Monitoring and Diagnostics5.1.1 Boiler OverviewThe Hawk 4500 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 5-1. Overview screen (steam)

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

Figure 5-2. 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.

CB780E CB120E

5-2 Part No. 750-427

Hawk 4500 Section 5 — Diagnostics and Troubleshooting

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.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 4500 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.

5.1.3 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 5-3. System Information

Part No. 750-427 5-3


5.1.4 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 5-1. 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 5-4. Modbus Diagnostics Screen

5-4 Part No. 750-427


5.1.5 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.

5.1.6 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 5-5. PLC Output Diagnostics (example: NRL relay)

Figure 5-6. PLC Hardware Overview

Part No. 750-427 5-5


5.1.7 PLC I/O StatusPLC I/O Status (two screens) 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).

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

Figure 5-7. PLC I/O Status

Figure 5-8. Combustion Curve Data

5-6 Part No. 750-427


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 5-9. Alarm Screen

Part No. 750-427 5-7


6.3 PLC Status The L36ERM has a bank of multi-state LEDs to indicate the controller’s operating status and communication activities. See tables below.

Table 5-2. 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 5-3. 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.

5-8 Part No. 750-427


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 5-3. PLC Communication LEDs (Continued)

Part No. 750-427 5-9


5.4 Fault ListTable 5-4. Hawk 4500 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.

5-10 Part No. 750-427


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 5-4. Hawk 4500 Fault List (Continued)


Part No. 750-427 5-11


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.



5-12 Part No. 750-427


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. 750-427 5-13


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)






5-14 Part No. 750-427


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. 750-427 5-15


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

Air Flow Bad Quality Trip Air Flow Transmitter Failure Analog input I:10/0 is outside or rangeRange > 3.3 maRange < 20.5 ma

Check Analog input wiring.Check jumper between V/I and Analog ComCheck transmitter

Fuel 1 Flow Bad Quality Trip Fuel 1 Flow Transmitter Failure with Fuel 1 selected

Analog input I:10/1 is outside or rangeRange > 3.3 maRange < 20.5 maFuel 1 Selected


Fuel 2 Flow Bad Quality Trip Fuel 2 Flow Transmitter Failure with Fuel 1 selected



FGR Flow Bad Quality Trip FGR Flow Transmitter Failure Analog input I:10/3 is outside or rangeRange > 3.3 maRange < 20.5 ma


High High Air/Fuel Deviation Trip

Absolute value of difference between air flow and fuel flow is higher then deviation trip setpoint

Absolute value of (Air Flow - Fuel Flow) > Deviation Trip Setpoint (K5)

Check Air Flow transmitterCheck Fuel Flow transmitterCheck damperCheck fuel valve



5-16 Part No. 750-427


High High FGR Flow Deviation Trip

absolute value of difference between FGR flow and FGR flow setpoint is higher then deviation trip setpoint

Absolute value of (FGR Flow - FGR Setpoint) > FGR Deviation Trip Setpoint

Check FGR Flow transmitterCheck FGR damperCheck fuel valve

Fuel 1 Flow Bad Quality Warning

Fuel 1 Flow Transmitter Failure with Fuel 2 selected



Fuel 2 Flow Bad Quality Warning

Fuel 2 Flow Transmitter Failure with Fuel 1 selected



Fuel 1 Temperature Bad Quality Warning

Fuel 1 Temperature transmitter failure

Analog input I:10/4 is outside or rangeRange > 3.3 maRange < 20.5 ma


High Air/Fuel Deviation Warning

Absolute value of difference between air flow and fuel flow is higher then deviation alarm setpoint

Absolute value of (Air Flow - Fuel Flow) > Deviation Alarm Setpoint (K5-K6)

Check Air Flow transmitterCheck Fuel Flow transmitterCheck damperCheck fuel valve

High FGR Flow Deviation Absolute value of difference between FGR flow and FGR flow setpoint is higher then deviation alarm setpoint

Absolute value of (FGR Flow - FGR Setpoint) > FGR Deviation Trip Setpoint

Check FGR Flow transmitterCheck FGR damperCheck fuel valve

Low Fire Hold - Output Characterizer Not Captured

At least one output characterizer is not populated with values

Access the output characterizer from the SAMA diagram



Part No. 750-427 5-17


5-18 Part No. 750-427

Section 6Parts

PLC & I/O

HMI

NOTE: Components and part numbers may vary. Contact C-B Aftermarket when ordering replacement parts.

Qty Description CB Part Number

1 Processor 1769-L36ERM 833-09240-011

1 Modbus Card 1769-SM2 833-03099-000

1 Digital Input Card 1769-IA16 833-02842-000

1 Digital Output Card 1769-OW8I 833-02872-000

1 Power Supply - PA4 833-02960-000

1 Analog Input Card 1769-IF8 833-03106-000

1 Analog Output Card 1769-OF8C 833-03107-000

1 Analog Input Card 1769-IF8 833-03106-000

1 Digital Input Card 1769-IA16 833-02842-000

1 Right End Cap 1769 833-02838-000

1 Memory Card SD 2GB 833-09969-000


1 Analog Input Card - Slot 8 1769-IF8 833-03106-000

1 Analog Output Card - Slot 9 1769-OF8C 833-03107-000

1 Analog Input Card - Slot 10 1769-IF8 833-03106-000

Qty Description CB Part Number1 Panel View + 7, 10 Inch Touch Screen 833-06004


Section 6 — Parts Hawk 4500

Electrical/Miscellaneous

Flame Safeguard


2 Communications Cable 826-00111-000

1 Label, Cleaver-Brooks 118-04756-000

1 5 Port Ethernet Switch 833-09181-000

1 AC Fan 001-01476-000

2 Circuit Breaker, 10 Amp 983-00081-000

1 Circuit Breaker, 5 amp 983-00088-000

1 Circuit Breaker, 6 amp 983-00083-000

1 Alarm Horn 817-01698-000

1 Alarm Horn Gasket 853-09159-000

1 24V DC Power Supply 832-03957-000

1 120 Volt Receptacle with 5 Amp Brkr 848-01437-000

1 Pushbutton 836-08852-001

1 Contact Block 177-00032-000

1 Timing Relay 175-00280-001

1 Warrick Relay 833-03767-000


1 CB-120E Chassis/Amplifier 833-03135-000

1 Programmer 833-03143-000

1 Display 833-03151-000

1 Wiring Sub-base 833-03153-000

1 Remote display kit 833-03156-000


1 Flame Detector UV Self Check 833-09260-000

6-2 Part No. 750-427

Hawk 4500 - Cleaver-Brookscleaverbrooks.com/docs/manuals/CB750-427-Hawk4500.pdf · 2019-06-07 · Cleaver-Brooks HAWK 4500 Boiler Control Operation Manual Manual Part No. 750-427

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