750-342 Hawk 4000 Jan 2016 PDF

Hawk 4000
Boiler Control
Operation Manual
750-342
01/2016
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 operators 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-Brooks
HAWK 4000
Boiler Control
Operation Manual
Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative
Manual Part No. 750-342

01/2016
Printed in U.S.A.
CONTENTS
Section 1
General
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hawk 4000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
New Features 2016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Provisions and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Burner Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Section 2
System Components
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
PLC Rack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Human-Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Steam Systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hot Water systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Section 3
Hardware Setup
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
DIN Rail Latch and Expansion I/O Module Locking Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Panel and Field Wiring Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
SM2 Module DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Burner Control Modbus Address and Baud Rate - CB780E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Burner Control Modbus Address and Baud Rate - CB120E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
PLC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Modbus Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Setting The Modbus Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Power/ Communications LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Moving The Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Section 4
System Configuration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Logging in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Configuration Screen #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Boiler Media and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Fuel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Actuator Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Configuration Screen #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Variable Frequency Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Economizer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Feedwater Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Feedwater Level Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Remote Modulation/Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Dual Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Hot Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Configuration Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Auxiliary Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Aux Analog Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
VFD Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Email Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
SMTP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Text/Email Contact List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
PanelView Plus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Installing a PV+ Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Change the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
Viewing the PV+ Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Section 5
Commissioning
Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Setting Combustion - Parallel Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Store Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Store Lightoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Curve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
No VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Combustion Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
Tuning and Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
Alarms and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Operating Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Outdoor Temperature Reset (Hot Water only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Hot Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Revert to Pilot (CB 120E only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18
Mix O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
Drive Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -5-19
Two Boiler Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
Lead Lag Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
Lead Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22
Thermal Shock Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-23
Two-Stage Economizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24
Section 6
Diagnostics and Troubleshooting
System Monitoring and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Burner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
System Information/PLC Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Modbus diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
PLC Output Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
PLC Hardware Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
PLC I/O Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
PLC Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Fault List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Section 7
Parts
APPENDIX A HAWK 4000 MASTER TAG LIST
APPENDIX B LOADING A PLC PROGRAM

Section 1
General
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hawk 4000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
New Features 2016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Provisions and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Burner Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
www.cleaverbrooks.com
Section 1 General Hawk 4000
1.1 Introduction
The Cleaver-Brooks HAWK 4000 is an exclusive Boiler Management and Control system specifically designed
to integrate the functions of a Programmable Boiler Controller and Burner Management Controller, as well as
other boiler operating and ancillary controls. The HAWK 4000 system incorporates a user-friendly, graphical
Human Machine Interface (HMI) that displays boiler parameters, fault annunciation and alarm history, as well
as providing access to boiler configuration and control functions.
Figure 1-1. Boiler Overview Screen
1. (Slot 0) - PLC L33ER

2. (Slot 1) - Modbus Module SM2
3. Power supply
4. (Slot 2) - Digital Inputs
5. (Slot 3) - Digital Outputs
6. (Slot 4) - Analog Inputs
7. (Slot 5) - Analog Outputs
8. (Slot 6) - Analog Inputs
9. (Slot 7) - Digital Inputs*
10. (Slot 8) - Analog Inputs*
11. (Slot 9) - Analog Outputs*
*optional
Figure 1-2. Typical Panel Layout
1-2 Part No. 750-342

Hawk 4000 Section 1 General
1.2 System Description

The HAWK 4000 Boiler Control System provides boiler firing rate control to maintain steam pressure (or hot
water supply temperature) at set point. Final control element(s) are controlled via Modbus communications
network to insure that the optimum fuel/ air ratio is maintained throughout the firing range.
The Hawk 4000 supports three fuel types. Fuel/air ratio is controlled using either parallel positioning or single-
point control method.
The Hawk 4000 can be monitored by Building/ Plant Automation Systems via an optional CB ProtoNode
protocol translator. Ethernet / Internet communication also enables remote monitoring of the Hawk 4000
Boiler Control System (additional software and/or hardware required).
The HAWK 4000 may be used on most types of steam and hot water boilers, including firetube, industrial
watertube, and commercial watertube. In addition to installation on new boilers, the HAWK 4000 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:
Level Master - 750-281

ProtoNode Gateway communication interface - 750-361
CB120E Burner Control - 750-264
CB780E Burner Control - 750-234
Variable Frequency Drives - 750-198
O2 Trim - 750-224
Draft Control - 750-221
Economizers (Single Stage and Two-Stage) - 750-266
Master Panel - 750-375
Part No. 750-342 1-3

1.3 Hawk 4000 System Features

Burner Control controls burner start and shutdown sequencing and flame and interlock monitoring
Compatible with CB780E and CB120E Burner Controls and Flame Scanners
Boiler Control monitors and displays connected boiler parameters (operating pressure or temperature, stack temperature, shell water
temperature, O2% etc.)
7 color touchscreen Human Machine Interface (HMI); 10 screen optional
Optimized boiler firing rate control
Alarm/Fault Indication and History -- first out annunciation with time stamp and displayed in order of fault occurrence
Dual set point capability
Thermal shock protection (includes warm-up routine, low fire hold & hot stand-by operation)
Remote modulation or remote set point
Return Temp monitor or Outdoor reset (hot water boilers)
Remote Modulation or Remote Set Point by communications (Ethernet)
Boiler efficiency calculation
Assured Low Fire Cut Off
External interlock with auxiliary devices (fresh air damper/louvers, circulating pumps, etc.)
High stack temperature alarm and shutdown
Built-in two-boiler lead/lag capability
Ethernet communications
Two firing modes: Parallel or Single-point
Revert to Pilot control function (requires CB120E burner control)
Supports control of a flue gas recirculation (FGR) damper
Supports up to two air dampers
Supports the control of a 2nd gas actuator (up to three fuels)
1, 2, or 3 element feedwater control (steam boilers)
OPC server software for building/plant automation system interface
Remote monitoring software
O2 monitoring and O2 trim (Option)
Mix O2 trim (Option)
Variable Speed Drive on combustion air fan (with bypass) (Option)
Combustion air temperature monitoring (option)
Analog input monitoring (up to 8 channels)
Expanded diagnostics
Email and text messaging for alarms/faults
Force Hot Standby by HMI
CB Level Master water level control interface
1.3.1 New features 2016

Beginning in 2016 the Hawk 4000 platform will feature a number of enhancements, summarized below:
HAWK 4000 previous versions HAWK 4000 new

Slot 8 customer defined analog input 4 channels (1769-IF4) 8 Channels (1769-IF8)
Slot 9 analog output 2 channels (1769-OF2) 4 channels (1769-OF4)
Number of Fuels 2 3
Second Gas Valve 2 fuels All 3 Fuels
Second Air Damper Not Available Available
VFD Bypass Fuel 1 Only All 3 Fuels
Level Control Not Available 1, 2 or 3 element
VFD PF400, 70, 700 PowerFlex 400, 70, 700, 753
Customer Defined Analog Inputs Predefined up to 4 (minimum 1) User defined up to 8 (minimum 3)
Force Hot Standby 3-position switch HMI pushbutton
VFD feedback 0-10 VDC 4-20 mA
Single-point air actuator 4-20 mA Modbus
Systems having the new features can be identified by the following program numbers:
PLC Standard Program: 98500553_000_00
HMI Standard Program: 98500554_000
HMI Standard Program metric units: 98500559_000
1-4 Part No. 750-342

Hawk 4000 Section 1 General
1.4 Safety Provisions and Diagnostics

1.4.1 Burner Management
Utilizes CB780E or CB120E Burner Control
Communicates with the PLC via Modbus
Burner Control Status, Faults and Diagnostics displayed on HMI or panel mounted burner control
Flame condition monitoring using either IR or UV Flame Scanner
CB780E
CB120E
Figure 1-3. FSG / Burner Control screen
1.4.2 Boiler Controls

Operating and Modulating Controls
Monitors Low Water Cut-Off
Monitors Burner Control alarm terminal
Non-Recycle Limit Relay de-energizes on PLC system errors or faults
Transmitter input signal out of range alarms
Actuator Modbus communication fault diagnostics
Password protected system configuration and system set up screens
Alarm Management incorporated into door-mounted HMI
Password protection of Programmable Controller Logic
Optional Variable Frequency Drive (VFD) fault shutdown
Part No. 750-342 1-5

1.5 Inputs and Outputs
Slot 0 Slot 1 Power Slot 2 - Digital Inputs Slot 3 - Digital Outputs Slot 4 - Analog Inputs
Processor Modbus Card Supply
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 O3/2 Non-Recycle Limit I4/2 O2
(Yokogawa) (NRLR)
I2/3 VFD Status O3/3 Prove Low Fire I4/3 Remote Mod/SP or 2 BLL
Press (Water Temp)
I2/4 VFD Bypass O3/4 Start Slave Blr (2 Blr L-L)
or Revert to Pilot *
I2/5 Ready To Start/ O3/5 Prove High Fire
Limits Closed
I2/6 Ext. Device Start O3/6 Alarm Output
Interlock (FAD)
I2/7 ALFCO or Boiler Start O3/7 Boiler Ready (L-L) or
(L-L) Revert to Pilot *
I2/8 Pilot Terminal
I2/9 Main Fuel Terminal
I2/10 Fuel 1 Selected
I2/11 Fuel 2 Selected
I2/12 FSG Alarm Terminal
I2/13 LWCO Shutdown
I2/14 Rem. Mod/SP, DSP,
or Avail. (L-L)
I2/15 Burner Switch
*With 2 boiler lead lag master boiler or if no lead lag selected, revert to pilot output is O3/7. With 2 boiler lead lag slave boiler or master panel, revert to pilot
output is O3/4.
Slot 5 - Analog Outputs Slot 6 - Analog Input Module Slot 7 - Digital Inputs Slot 8 - Analog Inputs
Address Name Address Name Address Name Address Name

O5/0 VSD Control Output I6/0 Stack Temp. (b4 Econ.) I7/0 Stack Damper Open Switch I8/0 Analog 0/Econ 2nd Stage
(Former I2/4) Temp In
O5/1 Control Output LL I6/1 Comb. Air Temperature I7/1 Combustion Air Pressure High I8/1 Analog 1/Econ 2nd Stage
Temp Out
O5/2 Draft Control I6/2 Water Shell (ST) Outdoor Temp I7/2 Force to Low Fire I8/2 Analog 2/Mix O2
(HW)
O5/3 Firing Rate Output/FW I6/3 Feed Water or Econ. Out Water I7/3 High Limit Control I8/3 Analog 3/Steam Flow
Valve Control Temperature (ST)
I6/4 Stack Econ.Out (ST) Return Water I7/4 ALWCO I8/4 Analog 4/Feedwater Flow
Temp (HW)
I6/5 Economizer Temp Water IN (ST) I7/5 Low Fuel 1 Pressure/Low Oil I8/5 Analog 5
Temp/Low F3
I6/6 VFD Feedback I7/6 High Gas Pressure/High Oil Temp/ I8/6 Analog 6
High F3
I6/7 Draft Signal I7/7 Low Oil Pressure I8/7 Analog 7
I7/8 High Oil Pressure Optional Module - 2 Stage Econ/Mix
I7/9 Oil Drawer Switch O2/2 or 3 FW, or aux analog inputs
Slot 9 - Analog Output I7/10 Atomizing Air Pressure Low
Address Name I7/11 Combustion Air Pressure Low
O9/0 Condensate Return Valve I7/12 High Water (ST) or Flow Sw. (HW)
O9/1 Makeup Bypass Valve Output I7/13 Stack Damper High Pressure
Switch
O9/2 Firing Rate Output for Balancing I7/14 Auxiliary #1
Valve
O9/3 Spare I7/15 Auxiliary #2 or Fuel 3 Selected
Optional module - required for 2 Optional Module - Required for Draft, 3rd
stage economizer Fuel, or expanded diagnostics
1-6 Part No. 750-342

Section 2
System Components
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
PLC Rack Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Human-Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Steam Systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Hot Water systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Section 2 System Components Hawk 4000
2.1 Overview
The principal components of the HAWK 4000 Boiler Control System are the Programmable Logic Controller
(PLC) and its associated input/output modules, the touch screen Human Machine Interface (HMI), and the
Flame Safety Control. The system also includes power supplies and various relays and circuit breakers.
The HAWK 4000 Boiler Controller is factory pre-programmed to work with most Cleaver-Brooks firetube and
watertube boilers, yet allows easy configuration for specific boiler applications. The Boiler Controller program
logic is password secured, ensuring tamper- proof controller operation. The Touch Screen HMI provides user-
friendly access to firing rate control functions, boiler diagnostics and alarm history, as well as connected
operating parameters. Burner management is handled by the proven CB780E or optional CB120E Flame
Safety Control.
Figure 2-1. Hawk 4000 PLC Rack
Slot Module
1
0 Processor 1769-L33ER
2 1 Modbus Card 1769-SM2
3 - Power Supply 1769-PA2
4 2 Digital Inputs 1769-IA16
5 3 Digital Outputs 1769-OW8I
6 4 Analog Inputs 1769-IF4
7 5 Analog Outputs 1769-OF4
8 6 Analog Inputs 1769-IF8
9 7 Digital Inputs [optional] 1769-IA16
10 8 Analog Inputs [optional] 1769-IF8
11 9 Analog Outputs [optional] 1769-OF4
2.2 PLC Rack Components

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.
2-2 Part No. 750-342

Hawk 4000 Section 2 System Components
A Right End Cap Terminator is required to complete the modular communication bus. It attaches to the right
side of the last module in the rack.
Optional modules can be added to the PLC to provide additional functionality.
DISCRETE and ANALOG Signal Types

Discrete inputs/outputs are used for signals taking on only one of
two possible states (on/off, open/close, etc.). The input state is
represented by a bit (0 or 1) in the control logic. Example:
Boiler Ready (yes/no)
Analog signals can assume almost infinite values within the fixed
analog input/ output current range of 4-20 mA. The Hawk 4000
PLC converts this current value to a range in engineering units.
Example:
Steam Pressure (0-150 PSI)
NOTE: The PLC program expects each device to be in a specific slot location. The HAWK 4000 controls
will not function unless all devices are properly installed and configured.
2.3 Human-Machine Interface (HMI)

The HMI displays numerous boiler parameters at a glance and provides easy menu navigation for configuring
system parameters, setting of combustion, monitoring the boiler processes, and managing and annunciating
system alarms.
The HMI is powered by 120VAC supply voltage and communicates with the PLC via Ethernet.
Figure 2-2. Hawk 4000 HMI
Part No. 750-342 2-3

Serial (not used

on standard system)
USB EtherNet 120VAC power
Figure 2-3. Hawk 4000 HMI Logic Module connections
2.4 Communications
2.4.1 Modbus
Modbus is an open serial protocol used by the HAWK 4000 system for sending
and receiving control commands, position data, and diagnostic data between the
PLC and attached devices. Modbus communications are managed by the SM2
module located to the right of the processor in slot 1.
HAWK 4000 devices that communicate using Modbus include the burner flame
safety control and the fuel, air, and FGR actuators. The Modbus communication
network allows burner control system status and fault information to be transmitted to
the PLC and displayed on the HMI screen, and in addition is used for actuator control,
feedback, and fault information.
2.4.2 Ethernet
The HAWK 4000 uses Ethernet for several communication functions:
Communication between the PLC and HMI. The Ethernet cable connecting the PLC
and HMI can be either a straight through or a crossover type.
Connection of the boiler control system to an existing infrastructure, i.e. plant Local
Area Network (LAN) Figure 2-4. SM2
Modbus Module
Integration with a Building/Plant Automation System (BAS)
Remote monitoring of boiler control system via the customer's Wide Area Network (WAN) or via the Internet
Connection of a laptop for diagnostics
Email or texting of boiler alarms to plant or service personnel
Ethernet/IP can also be used for control functions:
Networking multiple boiler controllers with a single BAS interface
Writing remote setpoint or remote start/stop of boiler
Networking multiple boiler controllers with a Cleaver-Brooks Master Panel
2.4.3 USB
USB 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.
2-4 Part No. 750-342

Hawk 4000 Section 2 System Components
BOTTOM OF CONTROLLER
PORT 1
PORT 2
USB
ETHERNET
Figure 2-5. L33ER PLC Communication Ports
2.5 Sensor Inputs

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

Steam Pressure ST Yes
Stack Temperature ST & HW Yes
Water Temperature ST Yes
Water Level ST Yes
Supply Temperature HW Yes
Outdoor Temperature HW Yes
Return Temperature HW Yes
Steam Flow ST Yes
Feedwater Flow ST Yes
O2 ST & HW Yes
Mix O2 ST & HW Yes
Comb. Air Temperature ST & HW Yes
2nd stage economizer ST Yes
2.5.1 Steam Systems:

Steam Pressure is the primary sensor input to the HAWK 4000 Controller in a Steam System. It transmits a
4-20mA process variable signal to the Controller that is used to control Firing Rate and the Operating Limit
Control.
Stack Flue Gas Temperature is used for High Stack Temperature alarms and shutdown. It is also used in the
boiler efficiency calculation.
Water Temperature (mandatory on steam boilers) measures boiler-shell water temperature and is used for
thermal shock protection and hot standby control on steam boilers. The standard location for the thermowell is
Part No. 750-342 2-5

a 1/2 NPT coupling at the right-hand side center-line of the boiler shell. If this location is not available, an
unused feedwater connection may be used.
Water Level sensor is OPTIONAL on steam boilers.
For optional 2 or 3-element feedwater control, Steam Flow and Feedwater Flow can be used in conjunction
with water level.
2.5.2 Hot Water systems:

Supply Temperature is the primary sensor input to the HAWK 4000 Controller in a Hot Water system. It
transmits a 4-20mA process variable signal to the Controller that is used to control Firing Rate and the
Operating Limit Control.
Outdoor Temperature is used in Hot Water Systems with the Outdoor Temperature Reset Option.
Return Temperature is used in Hot Water Systems with the Return Temperature option and is monitor only.
2-6 Part No. 750-342

Section 3
Hardware Setup
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
DIN Rail Latch and Expansion I/O Module Locking Levers . . . . . . . . . . . . . . . . . . . . 3-2
Panel and Field Wiring Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
SM2 Module DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Burner Control Modbus Address and Baud Rate - CB780E . . . . . . . . . . . . . . . . . . . . 3-3
Burner Control Modbus Address and Baud Rate - CB120E . . . . . . . . . . . . . . . . . . . . 3-6
PLC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Modbus Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Setting The Modbus Node Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Power/ Communications LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Moving The Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Section 3 Hardware Setup Hawk 4000
! Important
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.
3.1 Control Panel

This section will cover the initial system checkout to be done prior to configuring and commissioning the
system through the HMI menu system.
It is necessary to confirm that all of the integral components and interconnecting wiring are in place and
secure. Vibration and jarring from transport or installation may have loosened components or wiring terminals.
It is good practice to check all system components for integrity and tightness prior to initial power-up of the
system. Any external interlock and remote signal wiring should also be connected to the boiler controller.
3.1.1 DIN Rail Latch and Expansion I/O Module Locking Levers
Before powering up the control system for the first time, check that all the DIN rail latches and expansion
module locking levers are in place (see Figure 3-1 and Figure 3-2).
Figure 3-1. DIN rail latches
Figure 3-2. Expansion I/O Module locking levers

The module locking levers should all be securely seated to the left.
3-2 Part No. 750-342

Hawk 4000 Section 3 Hardware Setup
3.1.2 Panel and Field Wiring Terminations

Check that all factory wiring connections are tight and that field wiring terminations are completed and secure.
3.1.3 SM2 Module DIP Switch

Verify that the SM2 Module DIP switch setting is as shown below (the top switch is to the left, the bottom
switch is to the right).
DIP switch
settings: Top L,
Bottom R
Figure 3-3. SM2 module DIP switch setting
3.1.4 Burner Control Modbus Address and Baud Rate - CB780E

The CB780E Modbus node address should be set to 05 and the baud rate to 9600. Settings are made using
the 780E keypad display.
Press the left three buttons of the keypad display module for one second, then release.
DISPLAY Setup will appear.
Press the two ENTER buttons at the same time.

Press down arrow until MB ADDRESS is displayed.
Part No. 750-342 3-3

Press ENTER buttons at the same time.
Press down arrow twice.
Set Modbus address to 05 by using up and down arrow keys.

Press down arrow key to save changes.
Press down arrow key until MB BAUD is displayed.
3-4 Part No. 750-342

Press down arrow to select.

Using up or down arrow key select 9600.
Press ENTER keys at the same time.
Press down arrow key to save changes.
Part No. 750-342 3-5

Press upper arrow key to exit.
3.1.5 Burner Control Modbus Address and Baud Rate - CB120E
The CB120E has built-in Modbus capability; for proper communications the ModBus baud rate and node
address need to be correctly set. To check the settings, the CB120E must be powered.
Press the <BACK> or <NEXT> key on the CB120E display until the screen displays PROGRAM SETUP>.
Press the <MODE> then the <NEXT> key until the screen displays BAUD RATE.
Press <MDFY> and use the <BACK> or <NEXT> key to change to 4800. Press <MDFY> to save.
Press the <NEXT> key until UNIT ADDRESS # is displayed. To change the unit address, use the <BACK>
or <NEXT> key to change to 5. Press <MDFY> to save.
Press <MODE> to exit the menu.
RUN/REM/PROG
3.1.6 PLC Switch switch
Verify that the PLC switch is in the RUN position.
SD card
The boiler will not operate if the switch is in the PROG slot
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 S D 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).
3-6 Part No. 750-342

3.2 Modbus Actuators

3.2.1 Mounting
Fasten the actuator using bolts through the mounting bracket, threaded into the face of the actuator. Be
sure that the mounting surface rests flat against the mounting bracket and is secure.
The actuator output drive shaft should be connected to the valve shaft with a suitable coupling. The
coupling may be connected with set screws and pinned in position or secured with a key.
It is recommended that the actuator drive shaft remain decoupled from 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.
3.2.2 Electrical Connections

The 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.
Figure 3-4. Actuator Wiring, Quick Plug
Part No. 750-342 3-7

R R W
BL
BRN BRN
BRN BRN
ORG ORG
ORG ORG
BLK BLK
BLK BLK
RED RED
RED RED
G
Figure 3-5. Actuator wiring (hard wired)
3.2.3 Setting The Modbus Node Address

The actuators are required to have unique Modbus node addresses. The node address is set using a rotary
style switch located on the actuator front plate. Turn to the desired address using a small, flat bladed
screwdriver.
3-8 Part No. 750-342

Rotary switch - set

node address
Figure 3-6. Actuator, cover removed

Once the node address has been set, the actuator may be powered up.
Power must be cycled to the actuator before a new node address setting will be accepted by the actuator.
Actuator Node Address Table:

Actuator Address
Air Actuator 1 1
Fuel 1 Actuator 1 2
Fuel 1 Actuator 2 3
Air Actuator 2 4
Fuel 2 Actuator 1 5
Fuel 2 Actuator 2 6
FGR Actuator 7
Fuel 3 Actuator 1 8
Fuel 3 Actuator 2 9
All actuators must have a UNIQUE node address.
3.2.4 Power/ Communications LED

Each actuator has a green Power/ Communications LED. The LED can assume one of three states:
OFF - check that 24 VDC power is present. The LED is also OFF when pressing either the CCW or CW red
pushbutton.
ON Solid - power present but no commands received from PLC. ON Solid is the normal state for an actuator
not required by the PLC at the time - such as the Fuel 2 Actuator when the Fuel Selector is in the Fuel 1
position.
Rapid Flickering - actuator is responding to PLC commands and sending position data.
Part No. 750-342 3-9

3.2.5 Moving The Actuator

The actuator can be moved clockwise or counterclockwise by pressing either one of two red buttons located
on the actuator. 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.
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)
Figure 3-7. Actuator manual pushbuttons
3-10 Part No. 750-342

Section 4
System Configuration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Logging in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Configuration Screen #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Boiler Media and Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Fuel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Actuator Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Configuration Screen #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Variable Frequency Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Economizer Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Feedwater Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Feedwater Level Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Remote Modulation/Remote Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Dual Set Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Hot Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Boiler Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Configuration Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Auxiliary Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Aux Analog Input Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
VFD Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Email Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
SMTP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Text/Email Contact List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
PanelView Plus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Change the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Installing a PV+ Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Viewing the PV+ Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Section 4 System Configuration Hawk 4000
4.1 Introduction
The Hawk 4000 is equipped with a 7 (optional 10) color touch screen Human Machine Interface (HMI).
The HMI along with the Burner Control display are the points of interface for the operator to monitor and
control the boiler, and for the technician to configure and set up the system.
This section describes the HMI screens and their functions.
For information on the Burner Control (Flame Safeguard), refer to one of the following CB publications:
CB120E Burner Control 750-264
CB780E Burner Control 750-234
Figure 4-1. Hawk 4000
4.1.1 Logging in
Certain actions on the HMI require a password before allowing user input. The Hawk 4000 employs three
levels of security: Operator, Service, and Factory. When a password is required, the login entry window is
displayed.
Pressing <User Name> or <Password> will bring up an alphanumeric keypad. Use this to enter your user
name and password. A USB keyboard may also be used.
4-2 Part No. 750-342

Hawk 4000 Section 4 System Configuration
Press Enter after typing User Name and after typing Password. When both are entered, press <Login>.
Figure 4-2. Alphanumeric keypad
4.2 Main Menu

The 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>).
Part No. 750-342 4-3

Figure 4-3. Main Menu (all possible screens)
Figure 4-4. Main Menu (initial startup)
4-4 Part No. 750-342

4.3 Boiler Overview

The 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.
Firetube Steam Firetube HW
Flextube Steam Flextube HW
Model 4/5 Steam Model 4/5 HW
Figure 4-5. Boiler Overview screens
Part No. 750-342 4-5

4.4 System Configuration

The first step in commissioning t h e b o i l e r is
to configure the control system options. On the
M a i n Screen press <System Config >.
A warning m e s s a g e i s d i s p l a y e d :
Press <System Config> again; a final warning
screen will appear.
Press <System Config> to continue.
Password login will be required to configure the
system.
The following items are configurable when in system Figure 4-6. Warning
configuration.
Configuration Screen 1:
Boiler Media Steam or Hot Water
Boiler Type - Firetube, Flextube or M4/M5 boiler
Safety Valve Setpoint (Steam)/Max Rated Temperature (HW)
NOx Level (PPM)
Number of Fuels (up to 3)
Fuel Control Method (Parallel Positioning or Single Point)
Fuel Type and Turndown for each fuel
Steam transmitter span
FGR (Yes/No)
2nd fuel actuator (Yes/No) for each fuel
2nd Air Actuator
Flame Safeguard Selection (CB780E / CB120E)
Revert to Pilot (CB120E Only)
Revert to Pilot Signal Select (CB120E Only)
VFD Model / Min.% / Bypass / Ethernet communications
Remote Modulation/Setpoint Signal Selection
O2 Analyzer
O2 Trim
Low O2 Shutdown Option
Mix O2
Combustion Air Temp Option Selection
Level Master Option selection (Steam Boiler)
Expanded diagnostics (Slot 7) selection
Aux Analog Inputs (Slot 8) selection
2-Stage Economizer configuration (Steam Boiler)
Draft Control select
Feedwater level control selection and type - 1, 2, or 3-element (Steam Boiler)
Outdoor Temperature (HW)
Return Temperature (HW)
4-6 Part No. 750-342

2 Boiler Lead Lag / Master Panel Lead Lag select
Remote Modulation Source select (Analog Input / Communications)
Hot Standby
Remote Setpoint source select (Analog Input / Communications)
Dual Set Point
Outdoor Temp Reset (HW)
Enter customer name, boiler ID and serial number, Alarm Input #1-2 name if enabled.
Pressing <Next> from Configuration Screen #5 will show the Configuration Summary screen. Configured
values will be shown for all parameters.
If the <Confirm Options (Required)> pushbutton is visible, it must be pressed to accept the new system
configuration
Note - if a configuration setting is marked with an asterisk and the setting is changed, the
Combustion Curves will be erased.
! Caution
If System Configuration is entered with the boiler running, a safety
shutdown will occur. Repeated shutdowns or nuisance shutdowns
can cause premature equipment failure.
! Caution
The following screens should only be accessed by qualified
personnel. Selections should never be made while the boiler is in
operation.
Note: The boiler will not start while a System Config screen is displayed.
Note: The firing rate will be put into manual mode upon entering the System Config screen.
4.5 Configuration Screen #1

4.5.1 Boiler Media and Type
The first step in the configuration procedure is to select the boiler media and type.
Part No. 750-342 4-7

Figure 4-7. System Configuration Screen #1
Press <Boiler Media> for the following screen:
Figure 4-8. System configuration

Firetube is selected as the default boiler type. After selecting the boiler media (steam or hot water) additional
screen buttons will become available. Selecting Steam will bring up buttons for steam transmitter span,
safety valve setpoint, and NOx level. To change the default values, press the desired button and a keypad will
appear allowing user input.
Selecting boiler media will also bring up the <Next> button, allowing the user to advance to the next
configuration screen.
4-8 Part No. 750-342

The user must be logged in at the appropriate password level to change configuration data. If the user tries to
change configuration data without having proper access rights, a pop-up window will appear and a password
will be requested.
Figure 4-9. Boiler Media selected

If a valid user name and password are entered, the operator will be allowed to change data. The current user
login status can be seen at the top right of each screen.
The color of the pushbutton will also indicate if the user
has proper access rights.
CURRENT VALUE
Pressing the button of the value that needs modifying
will pop-up a numeric keypad, allowing the operator to RANGE
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 Popup keypad Invalid entry

Select Steam or Hot Water depending on the type of
system.
Boiler Type
The Boiler Type will display the proper Boiler graphic on the Boiler overview screen. The three choices for
Boiler Type are: Firetube, Flextube and M4/M5
Boiler Type is also used to set limits on the maximum entry allowed for Safety Valve Setpoint (steam) or Max
Rated Temperature (hot water).
Part No. 750-342 4-9

Safety Valve Setpoint Max

Firetube 400 psi
Flextube 250 psi
M4/M5 600 psi
Maximum Rated Temperature (Hot Water)

All Types = Between 200-400 Deg F
Safety Valve Setpoint (steam)

On a steam boiler, the proper safety valve setting should correspond to the pressure setting of the steam
safety valve(s) on the boiler.
! Warning
The safety valve setting is critical to the proper operation of the
boiler. An incorrect setting could lead to unsafe operation.
A hot water boiler is configured similarly. The max rated temperature of the boiler should be entered. This
number should not exceed the maximum design temperature of the boiler. Default for hot water boilers
is 250 F. Contact your local Cleaver-Brooks representative if you do not know the maximum temperature
rating of your boiler.
Steam Transmitter Span The span settings for the steam transmitter is adjustable. The Steam Transmitter
Span value cannot be set lower than the Safety Valve Setpoint and cannot be set higher than 1000. Initially
the Steam Transmitter Span is populated with a default value:
Safety Valve Steam Transmitter

Setpoint psi Span psi
15.0 or less 15.0
15.1 to 150.0 150.0
150.1 to 300.0 300.0
300.1 to 500.0 500.0
500.1 to 600.0 600.0
In hot water systems the supply temperature transmitter is not scalable. The transmitters used must be rated
to accommodate the required range:
If the Max Rated Temperature > 250 Deg F the Supply Temp Transmitter is set to 50-300 Deg F.
If the Max Rated Temperature = 250.1 Deg F or greater the Supply Temp Transmitter is set to 50-500 Deg F.
NOx Level (PPM)

Enter the NOx Level for this specific job.
NOx Level can range from 5-150 PPM and is initialized with a value of 60.0 PPM.
4-10 Part No. 750-342

Note: Remote Setpoint and Dual Setpoint options are NOT available for low emission steam boilers (NOx level
less than 60.0 PPM).
4.5.2 Fuel Configuration
Figure 4-10. Fuel configuration

Number of Fuels
Enter the Number of Fuels for this application.
Acceptable values are 1, 2, or 3.
Control Method
Select the type of combustion control method for this application.
Acceptable entries are Parallel Positioning or Single Point Positioning.
Fuel Type
Select the Fuel type for each fuel for this application.
When pressing the Fuel Type push button a selector is displayed:
Use the up/down arrows to select the correct fuel. Press the enter key to accept the selection. Press
<Close> to return to Configuration Screen #1.
Part No. 750-342 4-11

Turndown
Enter the Turndown for each fuel for this specific application.
The turndown entry affects the boiler efficiency calculations - it has no impact on the burner's actual
turndown. Turndown ratio is established during burner commissioning by a qualified burner technician.
4.5.3 Actuator Selection

FGR Actuator
The FGR actuator should be selected as Yes if it is present on this system. This actuator is only available for
parallel positioning control.
Fuel 1 Actuator 2
The Fuel 1 Actuator 2 should be selected as Yes if it is present on this system. This actuator is only available
for parallel positioning control.
Fuel 2 Actuator 2
Fuel 3 Actuator 2
Air Actuator 2
The Air Actuator 2 should be selected as Yes if it is present on this system. This actuator is only available
Figure 4-11. Actuator selection

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

4.6.1 Flame Safeguard
Figure 4-12. FSG configuration
4-12 Part No. 750-342

Select the type of Flame Safeguard used for the application.

The CB780E and CB120E are the two selections available on the Hawk 4000
If CB120E is selected the Revert to Pilot Option is available (not available on the CB780E).
Revert to Pilot
Revert to Pilot is selected if Yes is displayed on the <Revert to Pilot> push button.
If Revert to Pilot is selected there are two ways to initiate the Revert to Pilot sequence - either by Process
Variable (Steam Pressure/Water Supply Temperature) or by Digital Input.
If Process Variable is selected the setpoint for Revert to Pilot must be entered from the Revert to Pilot setpoint
screen.
Figure 4-13. Revert to Pilot - Steam Pressure
If Digital Input is selected, when discrete input I2/7 ALFCO is turned off, Revert to Pilot will be initiated.
! Caution
Revert to Pilot modes are to be determined in the field after careful
analysis of the load conditions that necessitate the use of this feature.
Care should be taken to avoid unnecessary recycling and damage to the
boiler equipment.
4.6.2 Variable Frequency Drives

The Hawk 4000 supports PowerFlex 400, 700, 70, and 753 drives. Other manufacturers VFDs are not
recommended. EtherNet communications to the VFD are available only when using a PowerFlex drive.
Part No. 750-342 4-13

VFD Model
Select the appropriate VFD Model for this specific job. The available options are None, PowerFlex, and Other
Mfg.
VFD Minimum Percent
This is the minimum percent output that the VFD will be commanded to run.
VFD Bypass
VFD Bypass should be selected Yes if VFD Bypass is used on this specific job.
An Air/Fuel curve must be configured for each fuel while in bypass mode.
VFD bypass allows the boiler system to keep the combustion blower motor running even if the Variable
Frequency Drive is taken out of the loop for any reason.
Figure 4-14. VFD configuration

VFD Ethernet
Select Yes if using Ethernet for VFD communications. If using Ethernet communications and <PowerFlex>
is selected as the drive model, you are required to specify the VFD type - PowerFlex 400, PowerFlex 70,
PowerFlex 700, or PowerFlex 753 drive.
All drive types use 4-20mA command and feedback.
4.6.3 Options
Oxygen Analyzer
The Oxygen (O2) Analyzer is available for monitoring stack flue gas oxygen concentration. The O2 Analyzer
transmits an analog signal to the controller. The O2 signal is used for Low O2 alarms, Low O2 Shutdown and in
calculating boiler efficiency. O2 concentration is displayed on the Boiler Overview and Firing Rate screens.
Figure 4-15. O2 Analyzer
O2 Trim
02 trim control is an integral part of the HAWK 4000 system. This feature affords additional control over fuel-to-
air ratios in the event of adverse atmospheric conditions or fluctuating fuel heating values.
The HMI has an 02 trim screen that displays O2 Actual concentration and O2 Setpoints. The Screen allows for
viewing and calibrating the Cleaver Brooks O2 Sensor. The Flue Gas O2 Control Screen can be accessed from
the HMI Main screen.
4-14 Part No. 750-342

Figure 4-16. Flue Gas O2 Control Screen
To view O2 trends or to adjust the O2 Trim PID tuning, press <Tuning & Trend>.
Figure 4-17. O2 Tuning & Trends

Low O2 Shutdown
Low 02 Shutdown is a feature that allow the boiler to be shutdown if O2 concentrations become too low.
Low O2 Shutdown can be enabled or disabled b y toggling O2 Shutdown (on the System Configuration
screen) between <Yes> and <No>.
If enabled the Low O2 Shutdown Setpoint and Low O2 shutdown time delay can be adjusted on the Alarms
and Limits screen.
Mix O2
This feature is for use with CB NTI burners in Ultra Low NOx applications. Mix O2 trim uses a probe mounted
in the boiler front head to monitor O2 levels in the combustion air in order to maintain optimum FGR rate.
If Mix O2 is selected in System Configuration, a Mix O2 control screen similar to Figure 4-16 will become
available, with sensor calibration, manual/auto control, and setpoint/actual value displays.
Part No. 750-342 4-15

Figure 4-18. Configuration Screen #3
Combustion Air Temperature

The Combustion Air Temp Sensor transmits a 4-20mA signal to the controller. The Combustion Air Temp signal
is used in the boiler efficiency calculation, and is displayed on the Boiler Overview screen.
Level Master
Select <Yes> if using a CB Level Master for water level control (steam boilers).
Feedwater Temperature
When selected, displays boiler feedwater temperature on Boiler Overview screen.
Expanded Diagnostics
Used for alarm annunciation. Digital input module (Slot 7) required.
Auxiliary Analog Inputs
Select if optional analog inputs are required. Slot 8 analog input module required.
Draft Control
Select <Yes> to make Draft Control setup and control screens accessible from the Main Menu. If using Hawk
draft control refer to manual 750-221.
Surface Thermocouple
Used on Hawk retrofits where a temperature probe is not available for shell water temperature input.
4.7.1 Economizer Configuration

If using an economizer, select <Yes> for Economizer 1 Stage or Economizer 2 Stage according to the type
of economizer. Selecting Yes will display the economizer graphically on the Boiler Overview screen.
Select <Temp In> and/or <Temp Out> to show the Stage 1 water temperature in/out.
NOTE: Hawk 4000 2-stage economizer control is for single boiler applications only.
4-16 Part No. 750-342

Figure 4-19. Economizer configuration
4.7.2 Feedwater Level Control

The Hawk 4000 can perform one, two, or three-element feedwater control. Selecting <Yes> for Feedwater
Level Control will display a button for Feedwater Control Type and a window showing the inputs necessary
for the chosen control mode.
One-element control requires a Level input at I4/1 (may be CB Level Master).
Two-element control requires Level as above and Steam Flow at Analog Input I8/3.
Three-element control requires Level and Steam Flow as above, and Feedwater Flow at Analog Input
I8/4.
One-element control - A control signal from the water level sensor is used as
1-element level control
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. LT
I4/1
Operator
setpoint SP PV
PID
CONTROL
CV
O5/3
To feedwater valve
Figure 4-20. 1-Element Control
Part No. 750-342 4-17


Two-element control - Similar to single element control; a control signal
from the water level sensor is used as the process variable. In addition, LT
steam flow is used as a feedforward signal to help the control output
respond to load changes. I4/1
Operator
setpoint SP PV
STEAM PID
FLOW FF CONTROL
I8/3
CV
O5/3
To feedwater valve

Three-element control - This is a cascade type
control involving two PID loops. The first loop is a LT FW
FLOW
2-element feedwater control. The output of this
loop is the setpoint for the second loop. The process I4/1 I8/4
variable for the second loop is feedwater flow. This
Operator
type of control provides better response to rapid setpoint SP PV PV
steam load changes. SP
PID PID
STEAM
FLOW FF CONTROL
1
CONTROL
2
I8/3
CV CV
O5/3
To feedwater valve
4.7.3 Feedwater Level Control Setup

If Level Master is selected its analog input will be scaled automatically on the Feedwater Level Setup screen
and will be used for the water level input at I4/1 for Feedwater Control.
If Level Master is not selected then a separate level transmitter must be used for the water level input at I4/1
and scaled on the Feedwater Level Setup screen.
Reverse Level Input Signal - The Feedwater Valve Input Signal may be reversed unless a Level Master is being
used.
Reverse Feedwater Valve Output - The Feedwater Valve Output may be reversed if required.
PID tuning parameters may be adjusted for all 3 control loops from this screen.
4-18 Part No. 750-342

Figure 4-23. Feedwater Level Setup Screen
Figure 4-24. Feedwater Level Control Screen
Part No. 750-342 4-19

Feedwater Valve% of Full Travel - Used to limit the control output to the valve.
Steam Flow% required for 2/3 Element Control - Although 2 or 3 element Feedwater Level Control is
selected, the Active Control will be 1 element until the Steam Flow% becomes greater than the Steam Flow%
Required for 2/3 Element Control. Once the steam flow exceeds this value 2 or 3 element Feedwater Control
(whichever is selected) will become active.
Steam Flow must be in units of Lb/Hr. These units are automatically configured for analog input I8/3.
Feedwater Flow may be in units of Lb/Hr, GPM, or GPH. If a unit other than Lb/Hr is selected for Feedwater
Flow a calculated value in Lb/Hr will be displayed on the HMI.
Figure 4-25. Configuration Screen #4
4.8.1 Lead Lag

CB 2 Boiler Lead Lag
For 2 Boiler Lead Lag select Master or Slave. If the boiler controller being configured has the header
transmitter connected to it, this boiler will be the Master - if not, it will be the Slave (Master as used
here should not be confused with the CB Master Lead Lag option below).
If Master is selected, the 2 Boiler Lead Lag Setup and Control screens will now be available from the Main
Menu.
CB Master Lead Lag

If the boiler will be utilized in a CB Master Panel control system, select <CB Master Lead Lag>. The boiler
controller will need the proper wiring connections with the master controller to function properly. See the CB
Master Panel manual (#750-375) for further information on Master Lead/Lag configuration and operation.
4.8.2 Remote Modulation/Remote Set Point
4-20 Part No. 750-342

Signals for Remote Modulation or

Remote Setpoint can be provided by
either an analog input signal or written
directly into the PLC by
communications (Ethernet). A green
indicator shows selections which may
be changed; selections with red
indicators may not be changed.
Remote Modulation by Analog Input
This configures the Boiler Controller to
receive a remote 4-20mA signal on
input I4/3 to control the firing rate of
the boiler.
The signal is scaled from 0-100%, (4ma = Low Fire and 20ma = High Fire).
Remote Modulation by Analog Input Signal Selection

The user can select between HMI or digital input to enable Remote Modulation.
Select <Digital In> if another control system will enable Remote Modulation by isolated contact input signal
(120 VAC) on digital input I2/14. When that input is de-energized, the Boiler Controller will revert back to
local firing rate control. If Remote Modulation operation will be enabled manually, select <HMI Input>.
Remote Modulation can then be enabled, by selecting the <Remote> button on the Firing Rate Screen.
If the PLC detects a bad analog signal, an alarm Remote Modulation Signal Failure is activated and the Firing
Rate reverts to the LOCAL setting on the HMI.
Remote Modulation by Communications

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

This configures the Boiler Controller to receive a remote 4-20mA signal on input I4/3 to vary the set point
of the boiler.
N o t e : Re m o t e S e t p o i n t i s not allowed for low emission s t e a m 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 t h e n be enabled, by selecting the <Remote> button on the Firing Rate Screen.
Part No. 750-342 4-21

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.
! 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.
4.8.3 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).
! Warning
Dual Set Point control should not be used on certain Low Emission
boiler systems. Low Emission boilers can be sensitive to changing
operating set points. Contact your Cleaver-Brooks representative to
determine if Dual Set Point control is allowed on your boiler. Failure
to follow these precautions may result in damage to equipment,
serious personal injury, or death.
4.8.4 Hot Standby

The Hot Standby function maintains a minimum water temperature to keep the boiler in a state of readiness
for a load demand. While operating, the boiler remains at the minimum firing rate and cycles on-and-off
relative to the Hot Standby water temperature set point. This set point is configured on the Setpoints screen
(accessed from the Main Screen).
4-22 Part No. 750-342

Hot Standby can be enabled or disabled by Pressing the Hot Standby button to toggle between <Yes> and
<No>. The boiler overview and firing rate screens will indicate when the boiler is in hot standby.
Hot Stand-By can be initiated manually by pressing <Force Hot Standby> on the Firing Rate screen. The
boiler will remain in standby until the button is again pressed.
See Section 5 - Commissioning for more on Hot Standby.
Outdoor Temperature Reset (Hot Water units only) With this option selected, a correction based on the
outdoor temperature will be applied to the operating set point. An outdoor temperature transmitter is
required on An alo g I npu t I 6/ 2 for this feature. When the outdoor temperature is selected for A n a l o g
I n p u t I 6 / 2 outdoor temperature is displayed on the boiler overview screen.
When Outdoor Reset is selected, the outdoor temperature and water temperature setpoints should be entered
from the Setpoints screen (See Section 5.5 - Setpoints) after system configuration is completed.

4.9.1 Boiler 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.
Figure 4-27. Boiler information

Once all the information is entered, press the carriage return button. The Boiler ID and Serial Number are each
limited to 20 characters, including spaces. The Customer name is limited to 30 characters, including spaces.
Auxiliary Alarm 1-2
Part No. 750-342 4-23

If the system has auxiliary alarms the text that is displayed when the auxiliary alarm is triggered can be
entered. To enter this information, press the text display button beneath the description. An alphanumeric
keypad pop-up window appears.
Once all the information is entered, press the carriage return button. The auxiliary alarms are each limited to
20 characters, including spaces.
Auxiliary alarm 1 must be wired to Slot 7 Input 14
Auxiliary alarm 2 must be wired to Slot 7 Input 15
For example: If Auxiliary Alarm 1 is entered as Water Pressure Low and Discrete Input I7/14 is On the alarm
displayed on the HMI for Auxiliary Alarm 1 will read Aux 1 - Water Pressure Low.
4.10 Configuration Summary

Once the System Configuration settings have been entered the entries can be viewed from the System
Configuration Summary screens.
Note: The Confirm Options push button is only visible if this is a new system configuration or a system
configuration parameter marked with an asterisk has been changed.
Figure 4-28. System Configuration Summary
To complete system configuration, press the <Confirm Options> pushbutton on the System Configuration
Summary Screen.
The Configuration selections may be changed after the HAWK 4000 is installed. However, for many of the
options, additional hardware is required to make the function work. Please refer to the parts section for the
required hardware.
4-24 Part No. 750-342

4.11 Auxiliary Analog Inputs

This optional feature provides 3-8 user defined inputs depending on the options selected. An 8 channel analog
input module is required in Slot 8.
2nd Stage Econ uses 2 user defined inputs
Mix O2 uses 1 user defined input
2 Element Feedwater uses 1 user defined input
3 Element Feedwater uses 2 user defined inputs
Figure 4-29. Aux Analog Inputs
4.11.1 Aux Analog Input Configuration

Go to <Analog Config [1-4]> to configure the auxiliary analog inputs.
Figure 4-30. Aux Analog Input Configuration
Part No. 750-342 4-25

Name - Enter any name (20 characters maximum).

Units - Enter any unit (8 characters maximum)
Input Range in EU - User defined scaling on analog input device
Enable Alarms:
Yes - For High Alarm, if input is greater than entry for 2 seconds, alarm will result
For Low Alarm, if input is less than entry for 2 seconds, alarm will result
Bad Quality Alarm alarm enabled for 1.5 seconds
No No Alarms Active
Flow Input - Yes will totalize analog input (if yes, time base for totalizer must be set).
Inputs can be monitored and trend screens accessed from <Analog Inputs [1 or 2]>:
Figure 4-31. Analog Inputs Screen
4.12 VFD Ethernet Configuration

If a PowerFlex drive will be connected to the Hawk 4000, the drive must have a properly configured Ethernet
communications module.
Once the drive is connected to the boiler network, the Ethernet communications option needs to be selected
via the HMI and the drive IP needs to be entered. With this step completed, the HMI can be used to download
the Cleaver-Brooks default drive parameters and to set motor nameplate data. If using a custom IP
configuration proceed as below, entering customer IP information where appropriate.
Configuring the PowerFlex drive Ethernet communications
The following procedure uses the VFD local display/keypad.
1.PowerFlex 400/70/700:Press the ESC key until the Parameters or Programming menu is displayed.
1.PowerFlex 753:Press the right arrow key until ENETR is displayed. Proceed to step 5.
2.From the Programming screen press until DSEL is selected.
4-26 Part No. 750-342

3.Press
4.Press or to highlight the communication module.

a.PowerFlex 400: 22-COMM-E.
b.PowerFlex 70/700: 20-COMM-E.
c.PowerFlex 753: ENETR
5.Press
6.Individual parameters can be accessed either by pressing or until the desired parameter
number is reached or by entering the parameter number via the keypad and pressing
7.Set BOOTP parameter to 0 (disabled).
a.PowerFlex 400: Parameter 02
b.PowerFlex 70/700: Parameter 03
7. PowerFlex 753: Set Parameter 05 [NetAddrSel] to 1
8.Reset the adapter by power cycling the drive.
a.Open the electrical disconnect.
b.Wait for capacitors to discharge (about 30-60 seconds depending on drive size).
c.Close the electrical disconnect.
9.Configure the IP address.
a.PowerFlex 400: Parameter 03 through 06
b.PowerFlex 70/700: Parameter 04 through 07
c.PowerFlex 753: Parameter 07 through 10
Default IP addresses are as follows
Boiler 1 Boiler 2 Boiler 3 Boiler 4

VFD 192.168.1.111 192.168.1.112 192.168.1.113 192.168.1.114
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).
Part No. 750-342 4-27

a.PowerFlex400: Parameter 15
b.PowerFlex70/700: Parameter 16
b.PowerFlex 753: NA
13.Reset the adapter by power cycling the drive.
a.Open the electrical disconnect.
b.Wait for capacitors to discharge (about 30-60 seconds depending on drive size).
c.Close the electrical disconnect.
The communications adapter is now configured.,
Configuring the HMI for PowerFlex drive Ethernet communication
Selecting PowerFlex as the VFD Model will make the VFD Ethernet button appear. When <VFD Ethernet>
is enabled, the VFD Type button will appear. Activate PowerFlex 400, 70, 700, or 753 based upon which
drive is used.
If <Other MFG> is selected for VFD Model, Ethernet communications are not available.
Figure 1. Configuration #2 screen - select PowerFlex Ethernet communications.

Once the VFD Ethernet option has been selected and the IP address of the PowerFlex drive has been
configured, press <Blower VFD Config> from the Main Screen to enter the Drive Configuration screen.
Figure 2. Initial PF Drive configuration screen.
4-28 Part No. 750-342

The IP address will initially be set to zeros. Also, if PowerFlex drives are de-selected, the IP address will be
zeroed. A warning will display whenever the address is not set or the PLC cannot connect to the drive. Enter
the IP address using the associated IP address octet button.
When the IP address has been entered, press the <Set VFD IP Address> button. Once Ethernet
communications have been established, the motor nameplate data and <Load C-B Defaults> buttons will
appear.
Figure 4. Motor nameplate information

Depending on the VFD type selected, the respective parameters for the motor nameplate data will be
displayed. Enter the corresponding information to properly configure the nameplate data.
The PowerFlex 70/700/753 drives have a few more parameters requiring configuration than the PowerFlex
400. Enter the corresponding information to properly configure the nameplate data.
The drive configuration is stored in the PLC and will be downloaded once the <Load C-B Defaults> button
is pressed. This process will take several seconds to complete. The <Load C-B Defaults Help> button
explains this process. Upon successful completion, the VFD will have its parameters set to Cleaver-Brooks
requirements.
Part No. 750-342 4-29

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.
4-30 Part No. 750-342

Figure 6. PowerFlex drive data
The Drive Faults screen will display the current drive fault (if present). Also displayed is a description of the
fault and recommended corrective actions. Press and hold the Last Drive Fault button to see the previous fault.
Figure 9. Current and Last drive fault information displayed on the Drive Faults screen.
Part No. 750-342 4-31

4.13 Email Setup

Email or text messages can be send directly from the PanelView Plus,
provided SMTP Server Configuration has been completed.
The PV+ must be at hardware revision 6.0 and firmware revision
7.0.20.13 or greater.
4.13.1 SMTP Configuration
SMTP (Simple Mail Transfer Protocol) is a standard protocol for the exchange of electronic mail over the
Internet. It will be the users responsibility to determine the SMTP server information for email configuration;
an example configuration is shown below. A help screen is available (press <SMTP Help>). Users IT
personnel should be consulted if necessary.
Figure 4-32. SMTP Configuration (example)
4.13.2 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.
4-32 Part No. 750-342

Figure 4-33. Email List
4.14 PanelView Plus Setup

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

Select Terminal Settings>Time/Date/Regional Settings>Date. The current date appears in the Year, Month,
and Day fields.
Figure 4-34.
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.
Part No. 750-342 4-33

Figure 4-35.
Press the Daylight Savings button to enable or disable daylight savings for the selected time zone. Daylight
Savings is set to Yes for all time zones except for Japanese, which does not support daylight savings.
Daylight savings changes are not permanently applied until you close the Time Zone screen.
Press the <Use Daylight Savings> button to select Yes or No. Click OK when done, then <OK> again to
return to Terminal Settings.
Figure 4-36.
4.14.2 Installing a PV+ Program

The following is a procedure to install a PanelView Plus program to the PV+ terminal using an SD memory
card.
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
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.
4-34 Part No. 750-342

Rockwell Software
RSViewME
Runtime
Filename.mer (example: 98500553_000.mer)
3.At this point if there is an Ethernet switch in the electrical control cabinet be sure that there are only 2
Ethernet cables plugged into the Ethernet switch. One cable from the PLC and one cable from the PV+.
4.Power up the PV+ and insert SD card or USB device into slot provided.
5.From the PV+ Configuration Mode (FactoryTalk ME Station), touch Terminal Settings [F4].
Figure 4-37.
6.From Terminal Settings, select File Management. Press the Enter arrow.
Part No. 750-342 4-35

Figure 4-38.
7.Select Copy Files. Press the Enter arrow.

8.Select Copy Applications. Press the Enter arrow.
9.Using the Source [F1] button, select External Storage 1 (the green bullet should move down to that
selection). Use the up/down buttons to select the application you want to load and then press the Destination
[F2] button. If the External Storage 1 cannot be selected, the PV+ cannot read the SD card. Try a different
card or verify the file structure on the SD card is exactly as stated in Step 2 of this document.
10.From the Copy Applications Destination screen, the green bullet should be on Internal Storage. If it is not
press Destination [F1] until the green bullet is on Internal Storage. Press the Copy [F2] button.
11.After the file is copied you should be back in the Copy Applications screen. Press Cancel [F8].
12.You should now be on the Copy Files screen. Press Close [F8].
13.You should now be on the File Management screen. Press Close [F8].
13a. You should now be on the Terminal Settings screen. Press Close [F8].
13b. Press Load Application [F1].
14.With the correct application highlighted and the green bullet on Internal Storage, load the application from
Internal Storage by pressing Load [F2].
4-36 Part No. 750-342

Figure 4-39.
15.A message appears asking Do you want to replace the terminal's current communication configuration
with the application's communication configuration?
IMPORTANT: Press Yes [F7] if this is the first time loading the application and communication has yet to be
established, otherwise press NO [F8].
16.You should be back on the FactoryTalk View ME Station screen. The application Filename.mer should
appear in the Current application window. Press Terminal Settings [F4].
II. DEFINE AN ETHERNET IP ADDRESS FOR THE PV+ TERMINAL

17.You should now be back on the Terminal Settings screen. Select Networks and Communications. Press the
Enter arrow.
18.From the Networks and Communications screen select Network Connections. Press the Enter arrow.
19.From the Network Connections screen select Network Adaptors. Press the Enter arrow.
20.From The Network Adaptors screen, with Built-in Ethernet Controller highlighted, press IP Address [F2].
Figure 4-40.
Part No. 750-342 4-37

21.From the IP Address screen select press the Use DHCP [F4] until the green bullet is in the No position and
the IP Address [F1] button is enabled.
Figure 4-41.
22.Press IP Address [F1] and enter the IP address with the pop-up keypad provided. The Standard IP
addresses for the PV+ are as follows:
NOTE: If the unit must be on a custom network, Ethernet parameters must be obtained from the users IT
department.
192.168.1.121 for Boiler 1
192.168.1.122 for Boiler 2
192.168.1.123 for Boiler 3
192.168.1.124 for Boiler 4
192.168.1.125 for Boiler 5
192.168.1.126 for Boiler 6
192.168.1.127 for Boiler 7
192.168.1.128 for Boiler 8
Press the Enter key.
23.Press Subnet Mask [F2] and enter 255.255.255.0

24.Press Gateway [F3] and enter 192.168.1.1
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].
4-38 Part No. 750-342

Figure 4-42.
III. SETTING RSLINX ENTERPRISE EHTERNET COMMUNICATIONS
29.You should be on the Networks and Communications screen.

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

33.Press the Backspace key and enter in the correct PLC IP address for this system
192.168.1.101 for Boiler 1
192.168.1.102 for Boiler 2
192.168.1.103 for Boiler 3
192.168.1.104 for Boiler 4
192.168.1.105 for Boiler 5
192.168.1.106 for Boiler 6
192.168.1.107 for Boiler 7
192.168.1.108 for Boiler 8
34.Press Enter
Part No. 750-342 4-39

35.Press OK [F7]
36.From the RSLinx Enterprise Configuration.
37.If the Ethernet IP address for the PV+ in this RSLinx Network needs to be revised arrow to highlight the
Ethernet IP address for the PV+.
Example: PV Plus, 192.168.1.121 (should be highlighted)
Press Edit Device [F1].
38.Press Device Address [F1].
39.Press the Backspace key and enter in the correct IP address for this PV+
192.168.1.121 for Boiler 1
192.168.1.122 for Boiler 2
192.168.1.123 for Boiler 3
192.168.1.124 for Boiler 4
192.168.1.125 for Boiler 5
192.168.1.126 for Boiler 6
192.168.1.127 for Boiler 7
192.168.1.128 for Boiler 8
40.Press OK [F7]
41.Press Close [F8]
42.From Networks and Communications Press Close [F8]
43.From Terminal Settings Menu, Select Startup Options.Press the Enter arrow.
44.Select FactoryTalk View ME Station Startup. Press the Enter arrow.
45.Using the On Startup [F1] button, put the green bullet to Run Current Application.
46.Press Run Options [F3]
47.Press Replace RSLinx Enterprise Communication [F1] until the green dot is on NO
a. Press Delete Log Files [F2] on every power cycle until green dot is on NO
48.From Run Options Press OK [F7]
49.Press OK [F7]
50.You should now be on the Terminal Settings screen. Press Close [F8].
51.Press Reset [F7]
52.Do you want to reset the terminal? .Yes [F7]. This takes a moment!
53.Terminal should reboot and run the application
54.Once application is running and communicating properly remove the SD card from the PanelView Plus
terminal. When all devices on the network are configured with a unique IP address the interconnecting
Ethernet cables between the configured devices may be plugged into the Ethernet switch and communications
verified.
55.END OF PROCEDURE
4.14.3 Viewing the PV+ Firmware

To check the PV+ firmware version, from the Configuration Mode main screen, go to Terminal
Settings>System>Information>About FactoryTalk View ME Station.
4-40 Part No. 750-342

Figure 4-43. PV+Firmware
4.15 Remote Monitoring

The PanelView Plus 6 HMI provides Web Server functionality, allowing for easy access to plant floor HMI
applications. There is no need to install any additional Rockwell software on the browser computer.
Once you have an Ethernet connection between a computer and the PanelView Plus 6 terminal, simply choose
a web browser such as Internet Explorer or Google Chrome and type in the IP address of the HMI running the
application you wish to view. Note there can only be one connection to an HMI at a time.
Figure 4-44. Remote Monitoring
Part No. 750-342 4-41

4-42 Part No. 750-342

Section 5
Commissioning
Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Setting Combustion - Parallel Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Store Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Store Lightoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Curve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
No VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Combustion Control Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Tuning and Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Alarms and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Alarms and Limits Screen 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Alarms and Limits Screen 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Operating Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Outdoor Temperature Reset (Hot Water only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Hot Standby . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Revert to Pilot (CB 120E only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Mix O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
VFD Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .-5-19
Two Boiler Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Lead Lag Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Lead Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Thermal Shock Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Two-Stage Economizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Section 5 Commissioning Hawk 4000
5.1 Commissioning the Actuators

When system configuration is complete, the <Calibrate Actuators> button will be available on the Main
screen and will indicate Required.
Figure 5-1. Actuator calibration required

Press <Calibrate Actuators> for the Actuator Commissioning screen, where air, fuel, and FGR actuators can
be individually selected for commissioning. On this screen, press <Commission Actuator> for the desired
actuator and read the warning screen which follows. In this example we will be commissioning the air
actuator.
Actuator Commissioning Screen Warning
Figure 5-2. Actuator commissioning

NOTE: Any combustion curves previously stored for the current fuel will be erased once the actuator
commissioning process has 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).
5-2 Part No. 750-342

Hawk 4000 Section 5 Commissioning
Figure 5-3. Actuator rotation

The default direction of rotation is counterclockwise for air and all fuels, and clockwise for FGR.
This screen also indicates the actuator torque rating (read via Modbus by the PLC).
Press <Next> after confirming the actuator direction of rotation. Next store the open and closed positions of
the actuator. Using the <Actuator Close (Open)> buttons, move the actuator to its fully open or closed
position (either position may be stored first). With the actuator fully open (closed), press <Store Open
(Close)>.
Figure 5-4. Actuator stroke

Note: CCW rotation requires the closed position to be greater than the open position.
CW rotation requires the open position to be greater than the closed position.
The actuator position is given in units of degrees x 10.
Valid range is 0 - 1100 units (0-110 degrees). Open and closed positions must be greater than 100 units (10
degrees) apart. If these conditions are not met, a Configuration Invalid error will result, and reconfiguration
of the actuator will be required.
When valid data have been entered, the <Save Air Actuator Configuration> button will appear. Press to save
data, then press <Next Actuator> and repeat the above steps.
Part No. 750-342 5-3

Invalid Data Save Data
Figure 5-5. Verify actuator calibration

<Test Close> and <Test Open> will move the actuator to the stored close/open position with a single press
of the button.
5.2 Setting Combustion - Parallel Positioning

When actuators for the currently selected fuel have been calibrated, the <Set Combustion> button will be
available on the Main screen. To begin the procedure, press <Set Combustion> and observe the warning that
follows.
Main Screen
Warning
Figure 5-6. Begin combustion setup

Press <I READ THE WARNING - I AM QUALIFIED> to continue. An additional warning screen will appear,
notifying the user that the boiler Operating Limit Relay will be de-energized during combustion setup.
Press <Confirm Combustion Setup> to continue.
5-4 Part No. 750-342

Figure 5-7. 2nd Warning
5.2.1 Store Purge

The first step is to store the Purge position. A help screen is available to guide the user through storing the
Purge (and Lightoff) positions:
Figure 5-8. Purge/Lightoff help

For a valid Purge position the air actuator(s) must be greater than 80% open. The VFD if present must be at
greater than 80% output. To set purge positions, use the <Dec> and <Inc> buttons to move the actuator/
VFD to the desired position.
Part No. 750-342 5-5

Figure 5-9. Combustion Setup

When purge position is set, press <Store Purge>. When prompted with Store Current Values?, press <Store
Purge> again to confirm or <Cancel> to re-adjust.
Figure 5-10. Store Purge
Note: If a VFD is present, the VFD purge value must be set above 80%.
5-6 Part No. 750-342

Figure 5-11. Combustion Setup - Purge value stored
5.2.2 Store Lightoff

When the purge position has been set, the <Store Lightoff> button will be available on the Combustion Setup
screen. After positioning the actuators in the lightoff position press <Store Lightoff>. A confirmation prompt
will appear as when storing the purge position. When both purge and lightoff have been set, the <Curve
Setup> button will be available.
All values except VFD must be less than 25% to store lightoff.
Figure 5-12. Store Lightoff
Part No. 750-342 5-7

Figure 5-13. Combustion Setup - Lightoff stored
5.2.3 Curve Setup

A help screen is available to guide the user through the steps of setting the combustion curve:
Figure 5-14. Combustion setup help

To set the combustion curve, the burner must be on. If all conditions to start the boiler have been met, the
<Burner Start> pushbutton will appear on the Combustion Setup screen. Press <Burner Start>; the purge
sequence will run and the actuators will return to the lightoff position. Press <Lightoff>. The Flame Safeguard
5-8 Part No. 750-342

will sequence through pilot trial and main flame and the burner will ignite. The actuators can now be
positioned for the first point.
10 points minimum must be stored for a valid curve (20 maximum allowed)
Points can not be skipped
Values for Air and Fuel Actuator 1 must be greater than previous values for a valid point to be stored.
Pressing <New Profile> at any time will erase the current curve.
When the combustion curve is complete (10 valid points are stored) the <Setup Complete> button will
appear; pressing this will go to the Combustion Control screen.
Pressing <Pt Adv Enable> will allow stepping through the combustion curve using <Next Point> and
<Prev Point>. With Points Advance disabled, the actuators will not move when <Next Point> or <Prev
Point> is pushed.
Figure 5-15. Combustion curve complete
5.3 Setting Combustion - Single Point Positioning

5.3.1 VFD or O2 Trim
If VFD or O2 Trim is selected, combustion setup is identical to parallel positioning, with the exception that
only the air actuator will be active. 10 points minimum are required for the combustion curve, with 20 points
maximum.
5.3.2 No VFD or O2 Trim

The combustion curve consists of 2 points. Only the air actuator will be active. Point 1 will be low fire; Point
2 will be high fire.
Single point positioning uses a Modbus actuator at Node 1.
Part No. 750-342 5-9

5.4 Combustion Control Screen

The 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.
Figure 5-16. Combustion Control screen
5.5 Firing Rate Screen

From the Firing Rate screen the boiler controls can be toggled between manual and automatic operation. With
<Manual> selected, the actuators will remain in their current positions until moved manually by the operator
using the Control Output <Decrease> and <Increase> buttons.
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.
5-10 Part No. 750-342

5.5.1 Remote Setpoint/Remote Modulation

If 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.
Remote modulation by digi-

tal input. Digital input is off; Remote mod. by HMI Remote mod. by Comms
Remote modulation by digital firing rate reverts to local
input is configured. Digital control
input is on and Remote Mod
selected.
Remote setpoint by digital

Remote setpoint by Digital
input. Digital input is off; Remote setpoint by Comms. Remote setpoint by HMI.
Input.
setpoint reverts to local con-
trol
Figure 5-17. Remote Modulation / Remote Setpoint
In the event of a bad remote signal, an alarm message will appear on the
screen and the control will revert to Local/Auto mode.
A help screens is available for Remote Modulation / Remote Setpoint
functions.
Figure 5-18. Remote bad

signal
Part No. 750-342 5-11

Figure 5-19. Rem Mod/Rem SP Help
5.5.2 Dual Setpoint

If 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.
Dual setpoint by digital Dual setpoint by digital

input. Digital input is on. input. Digital input is off. Dual setpoint by HMI. Set- Dual setpoint by HMI.
point 1 is selected. Setpoint 2 is selected.
Figure 5-20. Dual Setpoint
5.6 Tuning and Trends

For system variables subject to PID control, a Tuning & Trend screen is accessible from the appropriate screen,
as summarized below:
Screen Trended variable (press <Tuning & Trend> to view)

Firing Rate Steam Pressure (Water Temperature)
Flue Gas O2 Control Stack O2%
Mix O2 Trim Mix O2%
Feedwater Level Control Feedwater Level
Two Boiler Lead Lag Control Header Pressure (Temperature)
5-12 Part No. 750-342

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

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.
Figure 5-22. Analog Inputs screen

For flow inputs, the Hawk 4000 will keep totals and will display two values below the bar graph - the current
total (the first number) and the total at last reset. The units, input range, and totalizer time base are set on
the respective Analog Input Configuration screen.
Part No. 750-342 5-13

Figure 5-23. Analog Input Configuration
5.7 Alarms and Limits
Figure 5-24. Alarms and Limits screen 1
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:
5-14 Part No. 750-342

5.7.1 Alarms and Limits Screen 1

High Stack Temperature Alarm and Shutdown points.
Firing Rate Limit - This value can be used to limit the maximum control output from the HAWK 4000. A value
of zero will not allow the boiler to go above low fire.
Set Point Limiting - The minimum and maximum allowable setpoint values can be set here. The high and low
limit points affect the Set Point and the On and Off points on the setpoint screen.
Remote Set Point Scaling - The HAWK 4000 allows a remote 4-20 mA input signal to vary the setpoint. The
remote setpoint scaling enables the operator to zero and span the signal. The zero value will correspond to a
remote signal of 4 mA. The span value will correspond to a remote signal of 20 mA. Remote setpoint may be
enabled by a remote digital input signal or from the HMI Firing Rate screen.
Low Steam Pressure - Select Low Steam Pressure setpoint and Audible Yes/No. Alarm horn or bell must be
available for audible alarms.
Modulation rate limiting increases/decreases the rate of change of firing rate output. The value entered is the
number of seconds the control output will take to go between 0-100%
Remote Shutdown by Communications allows for remote start/stop of the boiler. If this feature is enabled, the
<On Comms Failure...> setting determines what the boiler will do upon a failure of remote communications
(shut down or remain in its last state).
Extended Pre-Purge Time - Extends pre-purge by up to 180 seconds.
Release from Lightoff Delay Time - delays the transition from lightoff to low fire by up to 180 seconds. Used
for combustion stabilization.
External Device Timer - allows the Start External Device (FAD) Output to remain energized for a period of time
(3-60 minutes) after a boiler shutdown.
5.7.2 Alarms and Limits Screen 2

Low 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).
Part No. 750-342 5-15

Figure 5-25. Alarms and Limits screen 2
5.8 Setpoints
<Set Points> allows adjustment of Setpoint 1 (and Setpoint 2 if Dual Setpoint is configured).
5.8.1 Operating Setpoint
Figure 5-26. Operating Setpoint

Steam Pressure (Water Temperature) setpoint and on/off differential are set here. If dual setpoint is selected,
the Operating Setpoint 2 can be entered from the HMI but the ON/OFF points are calculated using the same
dP/dT as Setpoint 1.
5-16 Part No. 750-342

Set Point = steam pressure (water temperature) operating setpoint

On Point = Set Point + (On dP% x Set Point)/100. Valid entries for On dP are from -50% to Off dP%.
Off Point = Set Point + (Off dP% x Set Point)/100. Valid entries for Off dP are from On dP% to the calculated
value where Off Point is not greater than the Safety Valve setpoint.
5.8.2 Outdoor Temperature Reset (Hot Water only)

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

When active, Hot Standby will cycle the boiler on if the shell water temperature (steam) or supply water
temperature (hot water) drops 5 degrees F below the Hot Standby Temp. The boiler will remain at low fire
until the shell water temperature reaches the Hot Standby Temp at which time the boiler will turn off. I2/7
ALFCO must be turned off to initiate Hot Standby.
Hot Standby can be initiated manually by pressing <Force Hot Standby> (on the Firing Rate Screen).
OUTDOOR RESET CURVE
Set point is linear in relation to the outdoor temperature.

Range for outdoor temperature transmitter is 4 ma = -50 deg F, 20 ma = 900 deg F.
In this example:
Outdoor Temp Range Low = 0 deg F
Set Point Range High = 200 deg F
Outdoor Temp Range High = 60 deg F
Set Point Range Low = 180 deg F
205
200
195
190 Setpoint
185
180
Outdoor 175
Temperature
-60 -40 -20 0 20 40 60 80
Figure 5-27. Outdoor reset curve
5.9 Revert to Pilot (CB 120E only)

Revert to Pilot (RTP) reduces cycling by eliminating the purge sequence.
When RTP is initiated the boiler returns to low fire, output O3/4 or O3/7 is energized, and the Revert to Pilot
signal is sent to the flame safeguard. The RTP sequence is managed by the FSG: pilot is energized, and upon
Part No. 750-342 5-17

proof of pilot the main gas valve de-energizes and the boiler remains on pilot. When demand returns or digital
input I2/7 is ON the main gas valve is energized.
When RTP is on a Rev to Pilot indicator will appear on the Boiler Overview and Firing Rate screens.
Initiated by process variable
If Initiate by process variable is selected, Revert to Pilot is initiated when steam pressure is greater than or
equal to Revert to Pilot Pressure and de-activated when steam pressure is below the boiler On Point.
Revert to Pilot Pressure = Off Point - (Revert to Pilot dP% x Off Point) [ensures that the RTP setting is always
less than or equal to the boiler off point]
Revert to Pilot Pressure must be greater than the boiler operating Setpoint or boiler On Point, whichever is
greater.
Figure 5-28. Revert to Pilot

Initiated by digital input
If Initiate by digital input is selected, the above screen will not be shown; Revert to Pilot will be initiated when
digital input I2/7 ALFCO is OFF.
5.10 O2 Trim
If O2 Trim was selected and an analyzer specified during system configuration, the <Flue Gas O2 Control>
button will appear on the Main screen.
Figure 5-29. O2 Trim
5-18 Part No. 750-342

O2 Trim is accomplished by means of the air actuator, or by the VFD if present (if VFD is in Bypass, the air
actuator is used). A manual operating mode is provided for diagnostic or testing purposes.
The CB O2 analyzer requires calibration on power up, if one week has elapsed since the last calibration, or if
initiated manually from the HMI. If using the Yokogawa analyzer, the PLC will expect a Sensor OK input from
the analyzer at input I2/2.
Once the O2 sensor is calibrated or Sensor OK input is on, the O2 setpoint is captured when setting
combustion curves.
PID control of O2 Trim is provided. Values can be adjusted by pressing <Tuning & Trend>. Defaults are P=3,
I=5, and D=0.
5.11 Mix O2
The Mix O2 feature is designed to improve combustion control for Ultra Low NOx (<9 ppm) systems. Requires
an 8 channel analog input module in Slot 8. If Mix O2 is selected during configuration, Input I8/2 will be
automatically configured with C-B default settings.
Using an O2 probe mounted in the boiler head, the FGR valve is modulated (more FGR for lower Mix O2 levels
and less FGR for higher Mix O2) to maintain optimum O2 levels throughout the firing range. A Mix O2 control
screen provides features similar to standard O2 Trim control:
Figure 5-30. Mix O2 Trim

The <Mix O2 Trim Max Trim Correction%> is the maximum trim value allowed, expressed as a percentage
of the FGR valve position. This value should be set small enough to prevent large excursions of the FGR valve,
and large enough to provide sufficient valve travel to achieve setpoint.
Mix O2 sensor calibration is activated on power up, if one week has elapsed since the last calibration, or if
initiated manually from the HMI.
5.12 VFD Data

If a VFD is present, <Blower VFD Data> will display a screen showing drive output and feedback, Low/High/
Lightoff settings, and current running frequency.
Part No. 750-342 5-19

Figure 5-31. VFD Data
5.13 PLC Ethernet Configuration

Multiple boilers on the same Ethernet network require unique IP addresses. To change a boilers configuration,
press the desired field in the Set New PLC Ethernet Configuration area. If user is logged in at the proper
level, a numeric keypad will appear. Enter the new data and press the enter key. When finished, go to
<Configure PLC Ethernet > and when prompted with Set PLC Ethernet Port Configuration? press <Yes>.
In order to configure the Ethernet port, the PLC switch must be in REM and the RUN LED must be GREEN.
Figure 5-32. Ethernet Configuration

After setting a new Ethernet configuration, communication between the HMI and PLC will be lost and must
be reestablished from the HMI. For more information, see Section 4 of this manual.
5.14 Two Boiler Lead Lag

The Two Boiler Lead Lag option allows one boiler controller to manage the start/stop and firing rate functions
of two boilers based on the load demand. The demand source is a header pressure (temperature) input at I4/3.
5-20 Part No. 750-342

Figure 5-33. Typical Two Boiler Lead/Lag system
If 2 Boiler Lead Lag Master is enabled in the Configuration section, two additional screens (for Lead Lag Setup
and Lead Lag Control) will be available.
Figure 5-34. 2 Boiler Lead Lag Setup
5.14.1 Lead Lag Setup
Select Modulation
Select Lead Lag (steam boilers only) or Unison modulation.
Part No. 750-342 5-21

Select Lead Lag

Select Master boiler as Lead and Slave boiler as Lag, or Master as Lag and Slave as Lead.
Lag Boiler settings

Start Point
Control output percentage of the Lead boiler at which the Start delay timer is activated. Valid values are
from Stop Point to 100%.
Start Delay
This time delay is activated when Lead boiler control output is greater than Start Point setting. After the time
delay has expired the Lag boiler is commanded to start. Valid values are from 0 to 600 seconds.
Stop Point
Control output percentage of the Lead boiler at which the Stop Delay timer is activated. Valid values are
from 0 to Start Point.
Stop Delay
This time delay relay is activated when the Lead's boiler control output is less then Stop Point setting. After
the time delay has expired, the Lag boiler is commanded to stop. Valid values are from 0 to 600 seconds.
Shutdown Delay
This is the length of time that the Lag boiler is allowed to run after the Stop Delay has expired. Valid values
are from 0 to 600 seconds.
Modulation Start
Control output to the Lead boiler at which the Lag boiler starts modulation. This parameter is only applicable
to Lead/Lag modulation. Valid values are from 0 to 100%.
Header Steam Pressure (Water Temp.) settings

Set the Lead Lag Set Point, On Differential, and Off Differential.
Remote Set Point Enable

Select if using a remote set point signal at I2/14.
Sequencing
If enabled, will automatically rotate the Lead and Lag boilers after Number of Days.
5.14.2 Lead Lag Control
5-22 Part No. 750-342

Figure 5-35. Lead Lag Control
The Lead Lag control screen has Auto/Manual controls and graphic displays showing operational data for each
boiler and for the Lead Lag System.
Note: In order for either boiler to be part of the lead lag sequence, <Remote> must be selected under
Control Mode on the boilers firing rate screen.
Lead Lag Modulation - The lag boiler starts when the lead boilers firing rate signal reaches the Start Point
(and the Start Delay has expired). The lag boiler starts modulating after the lead boiler reaches the configured
Modulation Start point. The lag boiler is commanded to stop when the lead boilers firing rate signal reaches
the Stop Point (and the Stop Delay has expired).
In the event of a header sensor failure, master and slave boilers will revert to local firing rate control.
Unison Modulation - Firing rates for both boilers are equal.
5.15 Thermal Shock Routine

Steam boilers
Thermal shock protection is activated when actual water temperature is below 60% of the steam saturation
temperature at set point. Maximum limit for CV for PID is based on water temperature and is determined by
a function generator. If boiler in thermal shock protection and release for modulation from FSG is true and
water temperature is above setting of hot standby off temperature*, thermal shock override timer is activated.
Thermal shock override timer is set for 126 seconds. Done bit of this timer resets the timer and increments
thermal shock override counter. Accumulated value of the counter is compared to the function generator
output and highest value is selected as maximum limit for CV. Every time thermal shock rung becomes true
output value from function generator is moved to the counter accumulated value. Thermal shock routine is
deactivated when hot water temperature reaches 90% of the saturated temperature at set point. It will not be
activated until temperature drops below 60% with fuel valve terminal de-energized. If fuel valve has been
de-energized for more than 8 hours, thermal shock protection is activated.
Part No. 750-342 5-23

Hot Water Boilers

Thermal shock protection is activated when actual water temperature is below minimum temperature (150F
for firetube boilers, 120F for FLX) Maximum limit for CV for PID is based on water temperature and is
determined by function generator. If boiler is in thermal shock protection and release for modulation from FSG
is true and water temperature is above setting of hot standby off temperature*, thermal shock override timer
is activated. Thermal shock override timer is set for 60 seconds. Done bit of this timer resets the timer and
increments thermal shock override counter. Accumulated value of the counter is compared to the function
generator output and highest value is selected as maximum limit for CV. Every time thermal shock rung
becomes true output value from function generator is moved to the counter accumulated value. Thermal shock
routine is deactivated when hot water temperature reaches 90% of set point. It will not be activated until
temperature drops below minimum temperature with fuel valve terminal de-energized. If fuel valve has been
de-energized for more than 8 hours, thermal shock protection is activated.
*If fuel valve is energized for more than 1 hour (Steam) or 10 minutes (Hot Water) and water temperature is still below standby
temperature setting. Firing rate will start ramping up as described.
5.16 Two-Stage Economizer

If the system has been configured with a 2-stage economizer (see Section 4), additional screens will be
available for economizer setup and control.
Figure 5-36. 2-Stage Economizer Setup

Setpoint is the economizer 2nd stage water out temperature that the PID loop will try to achieve by modulating
the condensate return and/or makeup bypass valves.
If the economizer 2nd stage water out temperature is below the Output Forced to Minimum value, the control
output will be set to Control Output Minimum%. Once temperature is above the Forced to Minimum
temperature, the condensate return and/or makeup bypass valves will begin to modulate.
5-24 Part No. 750-342

Output Split Range is only applicable if BOTH the condensate return and makeup bypass valves are enabled.
This is the value that determines how the control output is split between the two valves. At 0% the condensate
return valve will be disabled and only the makeup bypass valve will modulate. At 100% the makeup bypass
valve will be disabled and only the condensate return valve will modulate.
Output Force on PV Failure is the value that the control output is set to when the 2nd stage water out
temperature analog signal fails.
Manual/Auto controls and graphic/numeric displays for monitoring economizer operation are on the
economizer control screen:
Figure 5-37. 2-Stage Economizer Control
5.16.1 2-Stage Economizer Analog Inputs

Selecting a 2-stage economizer during the
configuration process will automatically configure
the appropriate analog inputs.
The default 4-20mA range values are suitable for
standard C-B transmitters; these values may be
changed by the user.
Figure 5-38. Two Stage Economizer Analog Input Screen
Part No. 750-342 5-25

5-26 Part No. 750-342

Section 6
Diagnostics and Troubleshooting
System Monitoring and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Burner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
System Information/PLC Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Modbus diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
PLC Output Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
PLC Hardware Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
PLC I/O Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Combustion Curve Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
PLC Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Fault List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Section 6 Diagnostics and Troubleshooting Hawk 4000
6.1 System Monitoring and Diagnostics

6.1.1 Boiler Overview
The Hawk 4000 has a number of features for monitoring system performance and diagnosing problems.
The Boiler Overview screen shows the primary operating details of the boiler and is accessible from the Main
screen.
Figure 6-1. Overview screen (steam firetube)
6.1.2 Burner Control

The Burner Control screen gives details on the installed Flame Safeguard (CB780E or CB120E).
CB780E CB120E
Figure 6-2. Burner Control screen
The status of the Flame Safety control is shown as well as the status of the inputs that allow the boiler to start.
The following flame safety status and boiler inputs are shown on the Burner Control screen:
Burner Switch - Indicates position of the burner switch.
Load Demand - When starting the boiler, there is a load demand if the system pressure (steam) or temperature
(hot water) is below the On Point. When system Pressure/Temperature exceeds the OFF point, No Demand
is indicated. When the system Pressure/Temperature drops below the On Point, load demand will again be
displayed.
6-2 Part No. 750-342

Hawk 4000 Section 6 Diagnostics and Troubleshooting
Limits -This is an indication of the status of the running interlocks on the boiler.
External Interlock - Feedback input from external interlock. When there is a load demand, and the burner
switch and limits are closed, the HAWK 4000 has isolated contacts (2.5A @ 125VAC) for output to an
external interlock device (e.g. fresh air damper, circulating pump). The boiler will start once the external
interlock is proven.
Note: The external interlock must be jumped if not used
ALFCO - Assured Low Fire Cut-Off. An external isolated start-stop contact can be provided to shut down the
boiler. This contact will drive the boiler to low fire prior to shut down.
Note: The ALFCO must be jumped if not used.
6.1.3 System Information / PLC Info

Press <System Information> from the Main screen to access. This screen shows boiler identification
information, the currently loaded programs for the PLC and HMI, elapsed time and cycles since last startup,
and network address information.
The screen duplicates the L33ER Status LEDs and in addition shows the current PLC firmware revision, serial
number, and PLC switch position.
Figure 6-3. System Information
Part No. 750-342 6-3

6.1.4 Modbus Diagnostics
Figure 6-4. Modbus Diagnostics Screen

This screen logs Modbus communication errors, actuator errors, and actuator manual pushbutton faults.
In the event of a Modbus communication fault, the screen will show the FSG status at the time of the fault
(up to 10 faults).
In the event of an actuator fault, the screen will indicate which actuator faulted and will display the actuator
fault code. Refer to Table 6-1 for fault descriptions and possible remedies.
<Reset All Counters> will set all counters to zero and record the time/date that the reset occurred.
Table 6-1. Actuator Error Codes

Error Code # Description Possible Remedies
0 No error, actuator is running normally -
1-7 Internal CPU self check error detected. A false positive Re-write the commanded position. Log when error
should be a rare occurrence. 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 actuators voltage regulator self checking detected Re-write the commanded position. Log when error
an error. A false positive should be a rare occurrence. 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.
6-4 Part No. 750-342

6.1.5 PLC Output Diagnostics

Press <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.
Figure 6-5. PLC Output Diagnostics (example: NRL relay)
6.1.6 PLC Hardware Overview

The PLC Hardware Overview screen shows a graphic representation of the PLC rack and gives the status of
each device. The devices shown on this screen must match exactly the actual devices in your PLC rack.
Figure 6-6. PLC Hardware Overview
Part No. 750-342 6-5

6.1.7 PLC I/O Status

The PLC I/O Status screen shows the status of all PLC inputs and outputs. Digital I/O points indicate On or
Off; analog I/O indicate Raw (analog signal in mA or Volts) and Value (corresponding value in engineering
units).
Figure 6-7. PLC I/O Status
6.1.8 Combustion Curve Data

This screen shows the combustion curve for the selected fuel.
Figure 6-8. Combustion Curve Data
6-6 Part No. 750-342

6.2 Alarms
If an alarm is active the alarm bell will be visible on all screens:
The bell signals the following conditions depending on its appearance:

Yellow flashing Warning - alarm
not silenced
Yellow solid Warning - alarm
silenced
Red flashing Fault - alarm not
silenced
Red solid Fault - alarm
silenced
Press the alarm bell or <Alarms> from the Main Screen to access the Alarm screen.
Figure 6-9. 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.
Part No. 750-342 6-7

6.3 PLC Status

The L33ER has a bank of multi-state LEDs to indicate the controllers
operating status and communication activities. See tables below.
Table 6-2. PLC Status LEDs

Indicator Status Description
RUN Off The controller is in Program or Test mode.
Green The controller is in Run mode.
FORCE Off No tags contain I/O force values. I/O forces are inactive (disabled).
Yellow I/O forces are active (enabled). I/O force values may or may not exist.
Flashing yellow One or more input or output addresses have been forced to an On or Off condition, but the forces have not
been enabled.
I/O Off The controller does not contain a project.
Green The controller is communicating with all of the devices in its I/O configuration.
Flashing green One or more devices in the I/O configuration of the controller are not responding.
Flashing red One of the following conditions exists:
The controller is not communicating with any devices.
A fault has occurred on the controller
OK Off No power is applied.
Green The controller is OK.
Flashing green The controller is storing a project to or loading a project from the SD card.
Red The controller detected a nonrecoverable major fault and cleared the project from memory.
Flashing red One of the following:
The controller requires a firmware update.
A major recoverable fault occurred on the controller.
A nonrecoverable major fault occurred on the controller and cleared the program from memory.
A controller firmware update is in process.
Dim green to red Save to Flash at power-down.
Table 6-3. PLC Communication LEDs
Indicator Status Description
NS (Ethernet Net- Off The port is not initialized; it does not have an IP address and is operating in BOOTP or DHCP
work Status0 mode.
Green The port has an IP address and CIP connections are established.
Flashing green The port has an IP address, but no CIP connections are established.
Red The port has detected that the assigned IP address is already in use.
Flashing red/green The port is performing its power-up self test.
6-8 Part No. 750-342

Table 6-3. PLC Communication LEDs (Continued)
LINK 1/LINK 2 Off One of the following conditions exists:

(Ethernet Link Sta- No link.
tus) 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- Off There is no activity to the SD card.

ity status)
Flashing green The controller is reading from or writing to the SD card.
Flashing red The SD card does not have a valid file system.
Part No. 750-342 6-9

6.4 Fault List

Table 6-4. Hawk 4000 Fault List
Fault Text System Failure Condition Recommended
Troubleshooting
Burner Control Alarm Alarm from flame safeguard Power present to PLC input I:2/ See flame safeguard manual.
alarm terminal. 12
Burner Control Modbus Comm Modbus communication to the Communication message error. Check for proper baud rate
Error flame safeguard failed. 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/ Correct per boiler operating or
13. level control manual.
Water Level High (Steam High water level warning Power present at PLC input I:7/ Check water level
Boiler) 12.
Aux Low Water Cutoff Auxiliary Low water Cut Off PLC Input I:7/4 is energized. Correct per boiler operating or
Alarm level control manual.
Boiler Operating Limits Open Boiler operating limits are With load demand present and Refer to the wiring diagram
open. burner switch On (I:2/15), and check for open limits. If
operating limits (I:2/5) are not expanded diagnostic item is
complete for 15 seconds. purchased, there will be an
indication for each specific
limit.
Boiler High Limit Alarm Boiler High Operating limits is PLC Input I:7/3 is energized. Refer to the wiring diagram
open and check for open limits.
External Interlock Alarm External device open. No power to the PLC input I:2/ Check external limits.
6. If external limits are not used,
put a wire jumper between
120 VAC and I:2/6.
Steam Pressure Low (Steam Steam pressure below low 1. Check alarm settings.
Boiler) pressure alarm set point. 2. Set low pressure alarm set
point to 0 to disable alarm.
Steam Pressure Sensor Failure Pressure Sensor failure Analog input I:4/0 is outside of Check analog input wiring.
(Steam Boiler) range. Check jumper between
Range> 3.3 ma V/I- and Analog Com
Range< 20.5ma
Water Temperature Sensor Temperature Sensor failure Analog input I:4/0 is outside of Check analog input wiring.
Failure (Hot Water Boiler) range. Check jumper between
Range> 3.3 ma V/I- and Analog Com
Range< 20.5ma
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 Water Flow Low warning Power present at PLC input I:7/ Check water flow or flow
Boiler) 12. switch
Water Temp Low (Hot Water Water Temp below low Temp 1. Check alarm settings.
Boiler) alarm set point. 2. Set low Temp alarm set
point to 0 to disable alarm.
Non-Recycle Limit Relay Failed PLC logic is not calling for non- Check wiring.
recycle limit relay output (O:3/
2), but pilot (I:2/8) or main fuel
(I:2/9) inputs are On
6-10 Part No. 750-342

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

Troubleshooting
Recycle Limit Relay Failed PLC logic is not calling for Check wiring.
recycle limit relay output (O:3/
0), but pilot (I:2/8) or main fuel
(I:2/9) inputs are On.
Water Level Signal Failure Water Level Sensor failure With water Level option Check analog input wiring.
(Steam Boiler) selected, Analog input I:4/1 is Measure analog input.
outside of range. View analog input Raw value
Range> 3.3 ma on the HMI PLC I/O status
Range< 20.5ma screen.
Remote Modulation Signal Remote Mod Signal Failed With remote mod by analog, Check analog input wiring.
Failure CB Master LLag, or 2 Boiler View analog input Raw value
LLag Slave option selected, on the HMI PLC I/O status
Analog input I:4/3 is outside of screen.
range. Measure analog input.
Range> 3.3 ma Verify System Configuration
Range< 20.5ma settings on HMI
Remote Set Point Signal Failure Remote Set point Signal Failed With remote set point by Check analog input wiring.
analog option selected, Analog View analog input Raw value
input I:4/3 is outside of range. on the HMI PLC I/O status
Range> 3.3 ma screen.
Range< 20.5ma Measure analog input.
Verify System Configuration
settings on HMI
Header Sensor Failure Header Sensor Signal Failed With 2 Boiler Lead Lag Master Check analog input wiring.
option selected, Analog input Measure analog input.
I:4/3 is outside of range. View analog input Raw value
Range> 3.3 ma on the HMI PLC I/O status
Range< 20.5ma screen.
Verify System Configuration
settings on HMI
Low Oxygen in Flue Gas Low Oxygen level in flue gas O2 level below alarm set point Check combustion.
or below 0.5% 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 Low Low Oxygen level in flue O2 level below Shutdown set Check combustion.
Shutdown gas point. 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 O2 analyzer calibration failed O2 signal (input I:4/2) must be Check wiring.
Failed (Only applicable to CB O2 between 4 and 6.5 VDC Repeat calibration.
analyzer) during calibration
Fuel 1, Fuel 2, Fuel 3 Gas Low fuel gas pressure/oil PLC Input I:7/5 is energized Check gas pressure regulator.
Pressure/Oil Temperature Low temperature Verify Oil Temperature for
specific Fuel Selected
Part No. 750-342 6-11


Troubleshooting
Fuel 1, Fuel 2, Fuel 3 Pressure/ High fuel gas pressure/oil PLC Input I:7/6 is energized Check gas pressure regulator.
Oil Temperature High temperature Verify Oil Temperature for
specific fuel selected
No Fuel Selected Fuel is not selected With burner switch On (PLC Check wiring. Depending on
Input I:2/15 energized), PLC the Number of Fuels selected,
inputs I:2/10, I:2/11, or Input either none of the Fuel Selected
I:7.15 are de-energized, or 2 PLC inputs are on, or more
are energized at the same time. than one Fuel Selected PLC
input is on.
Fuel 2 Pressure Low Low fuel oil pressure PLC Input Check oil pressure. Fuel 2 is
I:7/7 is energized 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 Flue gas temperature I:6/0 is Check for proper alarm setting.
the boiler outlet. above high temperature alarm Deposits on the pressure vessel
setting. surface.
Faulty temperature sensor.
Stack Temperature High High flue gas temperature at Flue gas temperature I:6/0 is Check for proper shutdown
Shutdown the boiler outlet. above high temperature alarm setting.
shutdown setting Deposits on the pressure vessel
surface.
Faulty temperature sensor.
Stack Damper High Pressure High flue gas pressure at the PLC Input I:7/13 is energized Check Draft Control Setup and
Switch Shutdown boiler outlet. 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 Combustion air actuator failed Difference between Check air damper for binding.
Deviation to go to position commanded and actual Check alignment.
position is not within Check wiring connections.
acceptable limits. Replace actuator.
Air/xxx Actuator Feedback Low Air actuator position feedback Actuator feedback signal is Check air damper for binding.
is low lower than -2.0% Check alignment.
Check wiring connections.
Re-commission actuator (Fuel
curve will be lost).
Replace actuator
Air/xxx Actuator Feedback High Air actuator position feedback Actuator feedback signal is Check air damper for binding.
is High greater than 102.0% Check alignment.
Replace actuator.
6-12 Part No. 750-342


Troubleshooting
Air/xxx Actuator Modbus Communication failure Check Modbus cable to the
Comm Error actuators.
Check connections on the
actuator.
Check Node address of the
actuator.
Air/xxx Actuator Manual PB Manual PB on actuator pressed Dont press manual pb while
Pressed while fuel valve is open. fuel valve is on.
Check for stuck manual button
on actuator.
Air/xxx Actuator Fault [X] Actuator Hardware Fault Modbus comms reports a fault Verify 24VDC on actuator.
on the actuator. Cycle Power on Control/
Actuator.
NOTE: ALL ACTUATORS WILL ANNUNCIATE THE ABOVE 6 FAULTS AND ARE ALL TROUBLESHOT IN THE SAME METHOD
XXX = Actuator
Drive Fault Blower Motor VFD alarm or VFD option is selected and no Check VFD for fault and
fault. power to PLC input I2/3 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 PLC Module faulted. PLC registers. With power off check
slot #] connection between modules.
Replace defective module.
Fault will indicate the slot of
the failed module.
Remote Communications BMS Heartbeat has timed out. The BMS Heartbeat must Verify Ethernet cabling.
Failure change states within 30 Verify Ethernet
seconds or an Error is communications to BMS.
generated. Verify BMS heartbeat.
Stack Temperature Sensor Sensor analog signal is either Analog input I:6.0 is outside of 1. Check sensor.
Failure too low or too high. range. 2. Check wiring.
Range> 3.3 ma 3. Measure analog signal 4-
Range< 20.5ma 20ma is valid.
4. View analog input Raw
value on the HMI PLC I/O
status screen.
Water Shell Temperature Sensor analog signal is either Analog input I:6.2 is outside of 1. Check sensor.
Sensor Failure (Steam Boiler) too low or too high. range. 2. Check wiring.
status screen.
Master PIDe Instruction Fault PIDe instruction fault. Call Cleaver-Brooks, Inc.
Technical Services
Outdoor Temperature Sensor Sensor analog signal is either Analog input I:6.2 is outside of 1. Check sensor.
Failure (Hot Water Boiler) too low or too high. range. 2. Check wiring.
status screen.
Part No. 750-342 6-13


Troubleshooting
Return Temperature Sensor Sensor analog signal is either Analog input I:6.4 is outside of 1. Check sensor.
Failure (hot water boilers) too low or too high. range. 2. Check wiring.
status screen.
Combustion Air Temperature Sensor analog signal is either Analog input I:6.1 is outside of 1. Check sensor.
Sensor Failure too low or too high. range. 2. Check wiring.
Range> 3.3 ma 3. Measure analog signal 4-20
Range< 20.5ma mA is valid.
status screen.
O2 Sensor Failure Only applicable to Yokogawa input I:2/2 must be On 1. Check sensor.
analyzer 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 Check air actuator for binding.
purge position. Check alignment.
Replace actuator
VFD Not At Purge VFD did not reach purge Check motor for binding.
position. Check wiring connections.
Re-commission (Fuel curve will
be lost).
Replace drive
XXX Actuator Not At Lightoff XXX actuator did not reach Check actuator for binding.
Lightoff position. Check alignment.
Replace actuator
Feedwater Temperature Sensor Sensor analog signal is either Analog input I:6.3 is outside of 1. Check sensor.
Failure (steam boilers) too low or too high. range. 2. Check wiring.
status screen.
Economizer Outlet Sensor analog signal is either Analog input I:6.3 is outside of 1. Check sensor.
Temperature Sensor Failure too low or too high. range. 2. Check wiring.
(steam boilers) Range> 3.3 ma 3. Measure analog signal 4-
status screen.
Stack Temperature Econ Out Sensor analog signal is either Analog input I:6.4 is outside of 1. Check sensor.
Sensor Failure (steam boilers) too low or too high. range. 2. Check wiring.
status screen.
6-14 Part No. 750-342


Troubleshooting
Economizer Inlet Temperature Sensor analog signal is either Analog input I:6.5 is outside of 1. Check sensor.
Sensor Failure (steam boilers) too low or too high. range. 2. Check wiring.
status screen.
I:8.0 Sensor Failure (user Sensor analog signal is either Analog input I:8.0 is outside of 1. Check sensor.
defined analog input) too low or too high. range. 2. Check wiring.
NOTE: All channels on slot 8, Range> 3.3 ma 3. Measure analog signal 4-
if user defined, will have this Range< 20.5ma 20ma is valid.
alarm for the specific channel. 4. View analog input Raw
status screen.
5. Disable Alarms for the
channel
I:8.0 Low Alarm (user defined . I:8/0 Scaled Value is below low 1. Check wiring.
analog input) alarm setting. 2. Adjust Alarm Limit for
NOTE: All channels on slot 8, Analog Input
if user defined, will have this 3. Measure analog signal 4-
alarm for the specific channel. 20ma is valid.
status screen.
channel
I:8.0 High Alarm (user defined . I:8/0 Scaled Value is above 1. Check wiring.
analog input) high alarm setting. 2. Adjust Alarm Limit for
NOTE: All channels on slot 8, Analog Input
if user defined, will have this 3. Measure analog signal 4-
alarm for the specific channel. 20ma is valid.
status screen.
channel
Mix O2 Sensor Calibration Mix O2 analyzer calibration MixO2 signal (input I:8/2) Check wiring.
Failed failed. must be between 4 and 6.5 Repeat Calibration.
VDC during calibration
Stack Pressure Transmitter With Draft Control enabled Analog input I:6.7 is outside of 1. Check Draft Signal.
Failed Sensor analog signal is either range. 2. Check wiring.
too low or too high. Range> 3.5 ma 3. Measure analog signal 4-
Stack Pressure High With Draft Control enabled, With draft control 1. Check alarm set point.
Pressure exceeds alarm enabled, stack pressure I:6.7 2. Check draft control.
setpoint. (draft) is higher 3. Check outlet damper
than high alarm set point
Stack Damper Not Open With Draft Control enabled With draft control 1. Make sure draft control is in
Stack damper failed to enabled, stack Auto Mode
Open to Full Open Limit Switch damper Input I:7.0 must be 2. Check wiring.
proven 3. Check Damper Open Limit
open before burner can start Switch
Econ 2nd Stage Outlet Water With 2 Stage Econ selected, Analog input I:8.1 is outside of 1. Check sensor.
Temp Sensor Failure sensor analog signal is either range. 2. Check wiring.
too low or too high. Range> 3.3 ma 3. Measure analog signal 4-
status screen.
Part No. 750-342 6-15


Troubleshooting
Econ 2nd Stage Outlet Water With 2 Stage Econ selected, With With 2 Stage Econ 1. Check alarm set point.
Temp High Outlet Water Temp exceeds enabled, Outlet Water Temp is 2. Check 2 stage econ control.
alarm setpoint higher
than high alarm set point
VFD Ethernet Communication VFD Not communicating to the PLC MSG instruction is in Verify Ethernet cabling.
Error PLC Error. 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 1. Check VFD for fault and
power to PLC input I2/3 alarms (see VFD manual for
corrective actions)
2. Check wiring to input 2 on
slot 3.
Check VFD parameters.
Check Analog Signal wiring 4-
20ma control and feedback.
Verify VFD digital outputs relay
status
6-16 Part No. 750-342

Section 7
Parts
PLC & I/O
Qty Description CB Part Number
1 Processor 1769-L33ER 833-05288-000
1 Power Supply 1769-PA2 833-02834-000
1 Modbus Card 1769-SM2 833-03099-000
* Digital Inputs - 1769-IA16 833-02842-000
1 Digital Outputs - 1769-OW8I 833-02872-000
1 Analog Inputs - 1769-IF4 833-02835-000
* Analog Outputs - 1769-OF4 833-09946-000
* Analog Input Module - 1769-IF8 833-03106-000
1 End Cap Right - 1769-ECR 833-02838-000
*1 Required; 2nd optional
HMI

1 7 inch Color Panel View Plus 817-04863-000
1 PV Plus Hawk Label, 7 Inch 118-03998-000
OPTIONAL:
1 10 Inch Color Panel View Plus 833-03512-000
1 Panel View Plus Hawk Label, 10 Inch 118-03997-000
Electrical

2 24V DC Power Supply - 120W 832-02404-000
10 Shielded Cable 950-00101-000
2 Relay, Terminal Block 833-03060-000
4 Din Rail, 1M Length, 1492-199-DR1 832-01951-000
1 Operator, 2 Position 836-00620-000
1 Contact Block, SPDT 836-00623-000
1 Alarm Bell 817-00239-000
Section 7 Parts Hawk 4000
Parallel Positioning Actuators

WITH QUICK CONNECT WITHOUT QUICK CONNECT
1 Modbus FX04-1, 3 ft-lb (4 N-m)* 945-00259-000 269-00221-000
1 Modbus FX20-1, 15 ft-lb (20 N-m)** 945-00260-000 269-00222-000
1 Modbus FX50-1, 37 ft-lb (50 N-m) 945-00261-000 269-00223-000
2 Modbus Actuator Cable Connector 826-00206-000
50 Modbus Actuator Cable 826-00205-000
*(Use on Fuel and FGR valves, except in High Torque applications)
**(Use On Combustion Air Damper, except in High Torque applications)
Ethernet

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

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

1 Steam 0-15 PSIG, 4-20ma 817-04866-000
1 Steam 0-150 PSIG, 4-20ma 817-04867-000
1 Steam 0-300 PSIG, 4-20ma 817-04868-000
1 Steam 0-500 PSIG, 4-20ma 817-04869-000
Smart transmitters, optional:
1 Steam 0-15 PSIG, 4-20ma 817-04873-000
1 Steam 0-150 PSIG, 4-20ma 817-04874-000
1 Steam 0-250 PSIG, 4-20ma 817-04875-000
1 Steam 0-300 PSIG, 4-20ma 817-04876-000
1 Steam 0-350 PSIG, 4-20ma 817-04877-000
1 Steam 0-400 PSIG, 4-20ma 817-04878-000
Temperature Transmitters

1 Supply Water (Section 4 boiler) 817-09776-000
1 Supply Water (Section 1 boiler) 817-09778-000
Comb. Air/Outdoor Temp/Stack 817-05166-000
Shell/Economizer In and Out/Return Water 817-05167-000
1 Return Water 817-09777-000
7-2 Part No. 750-342

Hawk 4000 Section 7 Parts
Flame Safeguard
FLAME SAFEGUARD KITS Qty Description CB Part Number

CB-780E w / iR Scanner CB-780E w / IR Scanner Kit 880-02117-000
1 CB-780 Programmer 833-03517-000
1 Wiring Sub-Base 833-02725-000
1 Infared Amplifier 833-03495-000
1 Purge Timer Card 833-02730-000
Not Part of 880-Kit 1 Scanner IR 817-1742 817-04133-000
CB-780E w / UV Scanner CB-780E w / UV Scanner Kit 880-02118-000
1 CB-780 Programmer 833-03517-000
1 Wiring Sub-Base 833-02725-000
1 U.V. Amplifier 833-02724-000
1 Purge Timer Card 833-02730-000
Not Part of 880-Kit 1 Flame Detector UV 817-01743-000
CB-120E w / IR Scanner CB-120E w / IR Scanner Kit 880-02097-000
1 Chassis/Amplifier 833-03708-000
1 Wiring Sub-Base open with terminal block 833-03153-000
1 Programmer 833-03143-000
1 Display 833-03151-000
1 ED-512 communications cable 4 foot long 833-03516-000
Not Part of 880-Kit 1 IR Scanner 817-2261 817-01933-000
CB-120E w / UV Scanner CB-120E w / UV Scanner Kit 880-02096-000
1 Chassis/Amplifier 833-03135-000
1 Wiring Sub-Base open with terminal block 833-03153-000
1 Programmer 833-03143-000
1 Display 833-03151-000
1 ED-512 communications cable 4 foot long 833-03516-000
Not Part of 880-Kit 1 UV Detector 817-02262-000
Stack Light
Standard Parts - Next 4 parts required for one standard unit.

1 Base 881-00364-000
1 Red Module 881-00361-000
1 Blue Module 881-00369-000
1 Green Module 881-00362-000
Optional
1 Yellow Module 881-00363-000
1 Audible Alarm Module* 881-00370-000
*Piezo alarm replaces the standard alarm bell.
Check insurance requirements before eliminating bell.
Part No. 750-342 7-3

Section 7 Parts Hawk 4000
Dual Fuel Kit

Bundled Kit - Gas Oil Selector 880-02112-000
1 Name Plate 118-01381-000
1 Contact Block, SPDT 836-00623-000
1 Operator, 3 Position 836-00627-000
O2 Trim

O2 Kit Yokogawa 880-02111-000
1 O2 Probe and Analyzer 985-00130-000
1 Mounting Kit 656-07576-000
25 Shielded Cable -25 950-00101-000
1 Combustion Air Temperature Sensor 832-02091-000
25 Thermocouple wire -25 950-00414-000
O2 Kit CB 880-02124-000
1 ECM controller with NTK Wide Band Sensor and Cable Harness 880-01847-000
1 O2 Sampling Probe Housing Assembly 040-00735-000
O2 Trim Gas/Oil - NO PP Kit 880-02125-000

1 Oxygen Analyzer, Digital, Yokogawa Model #ZR202G-040 985-00130-000
1 Mounting Kit 656-07576-000
25 Shielded Cable -25 950-00101-000
25 Thermocouple wire -25 950-00414-000
1 O2 Trim Pneumatic Panel 283-03183-000
1 Air Cylinder Assy O2 Trim System
Outdoor Reset
1 Outdoor Reset Thermocouple Option Consists of 832-1744, 008-2998,& 035-364
7-4 Part No. 750-342

Hawk 4000 APPENDIX A
APPENDIX A HAWK 4000 MASTER TAG LIST

Items in BOLD are write tags
FPC-N34 FPC-N35
PLC Point Name BACnet BACnet N2 Data N2 Point Modbus Lon Name Lon SNVT Type
Tagname Data Type Object Id Type Address Register
AB[0].0 Drive Fault BI 1 DI 1 10001 nvoDrvFlt_XXX SNVT_switch
AB[0].1 Modbus Comm Error BI 2 DI 2 10002 nvoModCmEr_XXX SNVT_switch
AB[0].2 Low Water BI 3 DI 3 10003 nvoLoater_XXX SNVT_switch
AB[0].3 Burner Control Alarm BI 4 DI 4 10004 nvoBrnCtrAlm_XXX SNVT_switch
AB[0].4 Boiler Limits Open BI 5 DI 5 10005 nvoBlrLimOpn_XXX SNVT_switch
AB[0].5 High Stack Temp. Alarm BI 6 DI 6 10006 nvoHiStkTpAl_XXX SNVT_switch
AB[0].6 High Stack Temp. Shutdown BI 7 DI 7 10007 nvoHiStTpShd_XXX SNVT_switch
AB[0].7 External Interlock BI 8 DI 8 10008 nvoExtIntrlk_XXX SNVT_switch
AB[0].8 PLC I/O module fault BI 9 DI 9 10009 nvoIOModFlt_XXX SNVT_switch
AB[0].9 Steam Sensor Fail BI 10 DI 10 10010 nvoStmSenFl_XXX SNVT_switch
AB[0].10 Air Actuator Out Of Position Alarm BI 11 DI 11 10011 nvoArAcPosAl_XXX SNVT_switch
AB[0].11 NG Actuator Out Of Position Alarm BI 12 DI 12 10012 nvoNGAcPosAl_XXX SNVT_switch
AB[0].12 F/A Ratio Controller Fault BI 13 DI 13 10013 nvoFARatCtFl_XXX SNVT_switch
AB[0].13 No Fuel Selected BI 14 DI 14 10014 nvoNoFlSel_XXX SNVT_switch
AB[0].14 Low ControlLogix Battery BI 15 DI 15 10015 nvoLoPLCBat_XXX SNVT_switch
AB[0].15 Non Recycle Limit Relay Fail BI 16 DI 16 10016 nvoNoRcLmRlF_XXX SNVT_switch
AB[1].0 Recyle Limit Relay Fail BI 17 DI 17 10017 nvoRecLmRlFl_XXX SNVT_switch
AB[1].1 Remote Modulation Signal Fail BI 18 DI 18 10018 nvoRemMdSgFl_XXX SNVT_switch
AB[1].2 Header Pressure Sensor Fail BI 19 DI 19 10019 nvoHdPrSnFl_XXX SNVT_switch
AB[1].3 Temperature Channel 0-5 Failure BI 20 DI 20 10020 nvoTpCh0_5Fl_XXX SNVT_switch
AB[1].4 Low O2 Alarm BI 21 DI 21 10021 nvoLoO2Alm_XXX SNVT_switch
AB[1].5 High Limit Alarm BI 22 DI 22 10022 nvoHiLimAlm_XXX SNVT_switch
AB[1].6 ALWCO BI 23 DI 23 10023 nvoALWCO_XXX SNVT_switch
AB[1].7 Low Gas Pressure/Low Oil Temp BI 24 DI 24 10024 nvoLoGsPrOTp_XXX SNVT_switch
AB[1].8 High Gas Pressure/High Oil Temp BI 25 DI 25 10025 nvoHiGsPrOTp_XXX SNVT_switch
AB[1].9 Low Oil Pressure BI 26 DI 26 10026 nvoLoOilPrs_XXX SNVT_switch
AB[1].10 High Oil Pressure BI 27 DI 27 10027 nvoHiOilPrs_XXX SNVT_switch
AB[1].11 Oil Drawer Switch Not Made BI 28 DI 28 10028 nvoOilDrwrSw_XXX SNVT_switch
AB[1].12 Low Atomizing Air Pressure BI 29 DI 29 10029 nvoLoAtmArPr_XXX SNVT_switch
AB[1].13 Low Combustion Air Pressure BI 30 DI 30 10030 nvoLoComArPr_XXX SNVT_switch
AB[1].14 AUX Alarm 1 - Stack Damper High BI 31 DI 31 10031 nvoAUXAlm1_XXX SNVT_switch
Pressure (next Gen)
AB[1].15 AUX Alarm 2 BI 32 DI 32 10032 nvoAUXAlm2_XXX SNVT_switch
AB[2].0 Blower On BI 33 DI 33 10033 nvoBlwOn_XXX SNVT_switch
AB[2].1 Purge Input BI 34 DI 34 10034 nvoPrgIn_XXX SNVT_switch
AB[2].2 Release To Modulate Input BI 35 DI 35 10035 nvoRel2ModIn_XXX SNVT_switch
AB[2].3 Low Fire Switch BI 36 DI 36 10036 nvoLoFirSw_XXX SNVT_switch
AB[2].4 High Fire Switch BI 37 DI 37 10037 nvoHiFirSw_XXX SNVT_switch
AB[2].5 Ready to start/Limits Closed BI 38 DI 38 10038 nvoRdy2Str_XXX SNVT_switch
AB[2].6 External Start Interlock BI 39 DI 39 10039 nvoExtStInlk_XXX SNVT_switch
AB[2].7 ALFCO BI 40 DI 40 10040 nvoALFCO_XXX SNVT_switch
AB[2].8 Pilot BI 41 DI 41 10041 nvoPilot_XXX SNVT_switch
AB[2].9 Main Fuel Valve Open BI 42 DI 42 10042 nvoMnFlVlvOp_XXX SNVT_switch
AB[2].10 Fuel 1 Selected BI 43 DI 43 10043 nvoFl1Sel_XXX SNVT_switch
AB[2].12 Heart Beat To BMS BI 45 DI 45 10045 nvoHrtBtBMS_XXX SNVT_switch
AB[2].13 LWCO Shutdown BI 46 DI 46 10046 nvoLWCOShdn_XXX SNVT_switch
AB[2].14 Remote Enable Input BI 47 DI 47 10047 nvoRmEnblInp_XXX SNVT_switch
Part No. 750-342 A-1

APPENDIX A Hawk 4000
AB[2].15 Burner Switch On BI 48 DI 48 10048 nvoBrnSw_XXX SNVT_switch

AB[3].0 Recycle Limit Relay BI 49 DI 49 10049 nvoRecLimRel_XXX SNVT_switch
AB[3].1 External Device Start BI 50 DI 50 10050 nvoExtDevSt_XXX SNVT_switch
AB[3].2 Non Recycle Limit Relay BI 51 DI 51 10051 nvoNoRecLmRl_XXX SNVT_switch
AB[3].3 Drive to Low Fire (FARC) BI 52 DI 52 10052 nvoDrv2LoFir_XXX SNVT_switch
AB[3].4 Start Slave Blr (2 Blr LL) BI 53 DI 53 10053 nvoStrtSlvBl_XXX SNVT_switch
AB[3].5 Load Demand Output BI 54 DI 54 10054 nvoLdDemOut_XXX SNVT_switch
AB[3].6 Alarm Output BI 55 DI 55 10055 nvoAlmOut_XXX SNVT_switch
AB[3].7 Boiler Ready (LL) BI 56 DI 56 10056 nvoBlrRdyLL_XXX SNVT_switch
AB[3].8 Boiler Load Demand BI 57 DI 57 10057 nvoBlrLdDem_XXX SNVT_switch
AB[3].9 Firing Rate Remote/Llag BI 58 DI 58 10058 nvoFrRatRmLL_XXX SNVT_switch
AB[3].10 Firing Rate Manual BI 59 DI 59 10059 nvoFirRatMan_XXX SNVT_switch
AB[3].11 Firing Rate Auto BI 60 DI 60 10060 nvoFrRatAuto_XXX SNVT_switch
AB[3].12 Hot Stand By BI 61 DI 61 10061 nvoHotStndBy_XXX SNVT_switch
AB[3].13 Warm Up BI 62 DI 62 10062 nvoWarmUp_XXX SNVT_switch
AB[3].15 Aux Alarm 3 BI 64 DI 64 10064 nvoAuxAlm3_XXX SNVT_switch
AB[4].0 Steam or Hot Water 1 = Steam BI 65 DI 65 10065 nvoStm_HWtr_XXX SNVT_switch
AB[4].1 Level Master Present BI 66 DI 66 10066 nvoLvlMstPrs_XXX SNVT_switch
AB[4].2 Variable Speed Drive Present BI 67 DI 67 10067 nvoVarSpDrPr_XXX SNVT_switch
AB[4].3 Economizer Present BI 68 DI 68 10068 nvoEcPrs_XXX SNVT_switch
AB[4].4 Combustion Air Temp. Present BI 69 DI 69 10069 nvoCmArTpPrs_XXX SNVT_switch
AB[4].5 Economizer Inlet FW Sensor Present BI 70 DI 70 10070 nvoEInFwSnPr_XXX SNVT_switch
AB[4].6 O2 Analyzer Present BI 71 DI 71 10071 nvoO2AnlzrPr_XXX SNVT_switch
AB[4].7 Feedwater or Return Temp. Present BI 72 DI 72 10072 nvoFdWRtTpPr_XXX SNVT_switch
AB[4].8 Outdoor Reset Selected BI 73 DI 73 10073 nvoOutResSel_XXX SNVT_switch
AB[4].9 Parallel Positioning Selected BI 74 DI 74 10074 nvoParPosSel_XXX SNVT_switch
AB[4].10 Two Boiler Lead Lag Master Select BI 75 DI 75 10075 nvo2BLLMstSl_XXX SNVT_switch
AB[4].11 Two Boiler Lead Lag Slave Select BI 76 DI 76 10076 nvo2BLLSlvSl_XXX SNVT_switch
AB[4].12 Master Panel Select BI 77 DI 77 10077 nvoMstPnlSel_XXX SNVT_switch
AB[4].13 Hot Stand By Select BI 78 DI 78 10078 nvoHotStbySl_XXX SNVT_switch
AB[4].14 Dual Setpoint Select BI 79 DI 79 10079 nvoDualSPSel_XXX SNVT_switch
AB[4].15 Slot 8 Ch 0 Analog Input Selected BI 80 DI 80 10080 nvoSlCh0AISl_XXX SNVT_switch
AB[5].3 Honeywell or Fireye 1 = Fireye BI 84 DI 84 10084 nvoHnywFreye_XXX SNVT_switch
AB[5].4 High Water Alarm BI 85 DI 85 10085 nvoHiWtrAlm_XXX SNVT_switch
AB[5].5 Oil Actuator Out Of Position Alarm BI 86 DI 86 10086 nvoOlAcPsAlm_XXX SNVT_switch
AB[5].6 FGR Actuator Out Of Position Alarm BI 87 DI 87 10087 nvoFGRAcPsAl_XXX SNVT_switch
AB[5].7 Air Actuator Feedback Fail Low Alarm BI 88 DI 88 10088 nvoAAcFdLoAl_XXX SNVT_switch
AB[5].8 Air Actuator Feedback Fail High Alarm BI 89 DI 89 10089 nvoAAcFdHiAl_XXX SNVT_switch
AB[5].9 NG Actuator Feedback Fail Low Alarm BI 90 DI 90 10090 nvoNGAFdLoAl_XXX SNVT_switch
AB[5].10 NG Actuator Feedback Fail High Alarm BI 91 DI 91 10091 nvoNGAFdHiAl_XXX SNVT_switch
AB[5].11 Oil Actuator Feedback Fail Low Alarm BI 92 DI 92 10092 nvoOilFdLoAl_XXX SNVT_switch
AB[5].12 Oil Actuator Feedback Fail High Alarm BI 93 DI 93 10093 nvoOilFdHiAl_XXX SNVT_switch
AB[5].13 FGR Actuator Feedback Fail Low Alarm BI 94 DI 94 10094 nvoFGRFdLoAl_XXX SNVT_switch
AB[5].14 FGR Actuator Feedback Fail High Alarm BI 95 DI 95 10095 nvoFGRFdHiAl_XXX SNVT_switch
AB[5].15 VSD Deviation Alarm BI 96 DI 96 10096 nvoVSDDevAlm_XXX SNVT_switch
AB[6].0 Increase MSG Register Size Bit (Cleaver BI 97 DI 97 10097 nvoIncRegSiz_XXX SNVT_switch
Brooks Only)
AB[6].1 Air/Fuel Deviation Alarm BI 98 DI 98 10098 nvoArFlDevAl_XXX SNVT_switch
AB[6].2 2nd Stage CEC Economizer Selected BI 99 DI 99 10099 nvo2StCECEcS_XXX SNVT_switch
A-2 Part No. 750-342

AB[6].3 Fuel3 Actuator 1 Out Of Position Alarm BI 100 DI 100 10100 nvoFl3AcPsAl_XXX SNVT_switch
AB[6].4 Fuel3 Actuator 1 Feedback Fail Low BI 101 DI 101 10101 nvoFl3AFdLoA_XXX SNVT_switch
Alarm
AB[6].5 Fuel3 Actuator 1 Feedback Fail High BI 102 DI 102 10102 nvoFl3AFdHiA_XXX SNVT_switch
Alarm
AB[6].6 Stack Pressure Input Fail BI 103 DI 103 10103 nvoStkPrInFl_XXX SNVT_switch
AB[6].7 High Stack Pressure Alarm BI 104 DI 104 10104 nvoHiStkPrAl_XXX SNVT_switch
AB[6].8 Stack Damper Not Open Alarm BI 105 DI 105 10105 nvoStDpNtOAl_XXX SNVT_switch
AB[6].9 O2 Calibration Failed BI 106 DI 106 10106 nvoO2ClRtFld_XXX SNVT_switch
AB[6].10 Low Steam Pressure/Water Temp Alarm BI 107 DI 107 10107 nvoLoStPWTAl_XXX SNVT_switch
AB[6].11 Processor Test Fail Alarm BI 108 DI 108 10108 nvoPrTstFlAl_XXX SNVT_switch
AB[6].12 O2 Trim Internal Alarm BI 109 DI 109 10109 nvoO2TrmInAl_XXX SNVT_switch
AB[6].13 Firetube or Flextube 1 = Flextube BI 110 DI 110 10110 nvoFir_FlxTb_XXX SNVT_switch
AB[6].14 Reserved for Cleaver Brooks BI 111 DI 111 10111 nvoAB_6_14_XXX SNVT_switch
AB[6].15 VSD Limits Internal Alarm BI 112 DI 112 10112 nvoVSDLmInAl_XXX SNVT_switch
AB[7].0 Gas Actuator #2 Out Of Position Alarm BI 113 DI 113 10113 nvoGsAc2PsAl_XXX SNVT_switch
AB[7].1 Gas Actuator #2 Feedback Fail Low Alarm BI 114 DI 114 10114 nvoGsAc2LoAl_XXX SNVT_switch
AB[7].2 Gas Actuator #2 Feedback Fail High BI 115 DI 115 10115 nvoGsAc2HiAl_XXX SNVT_switch
Alarm
AB[7].3 Actuator Modbus Communication Error BI 116 DI 116 10116 nvoAcModCmEr_XXX SNVT_switch
AB[7].4 Air Actuator Modbus Comm Error Node 1 BI 117 DI 117 10117 nvoAAcMdCEr1_XXX SNVT_switch
AB[7].5 Gas Actuator Modbus Comm Error Node BI 118 DI 118 10118 nvoGsAMdCEr2_XXX SNVT_switch
2
AB[7].6 Gas Act #2 Modbus Comm Error Node 3 BI 119 DI 119 10119 nvoGsA2MdCE3_XXX SNVT_switch
AB[7].7 Oil Actuator Modbus Comm Error Node 5 BI 120 DI 120 10120 nvoOAcMdCEr5_XXX SNVT_switch
AB[7].8 FGR Actuator Modbus Comm Error Node BI 121 DI 121 10121 nvoFGRAMdCE7_XXX SNVT_switch
7
AB[7].9 Reserved BI 122 DI 122 10122 nvoAB_7_9_XXX SNVT_switch
AB[7].10 Reserved BI 123 DI 123 10123 nvoAB_7_10_XXX SNVT_switch
AB[7].11 Second Stage Outlet Water Temp Sensor BI 124 DI 124 10124 nvo2SOtWTSnF_XXX SNVT_switch
Failed
AB[7].12 Water Temperature Second Stage Out BI 125 DI 125 10125 nvoWtTp2SOtH_XXX SNVT_switch
High
AB[7].13 Air Actuator Manual Override Pushbutton BI 126 DI 126 10126 nvoAAcMnOBPr_XXX SNVT_switch
Pressed
AB[7].14 Gas Actuator #1 Manual Override BI 127 DI 127 10127 nvoGAc1MOBPr_XXX SNVT_switch
Pushbutton Pressed
AB[7].15 Gas Actuator #2 Manual Override BI 128 DI 128 10128 nvoGAc2MOBPr_XXX SNVT_switch
Pushbutton Pressed
AB[8].0 Oil Actuator Manual Override Pushbutton BI 129 DI 129 10129 nvoOAcMnOBPr_XXX SNVT_switch
Pressed
AB[8].1 FGR Actuator Manual Override BI 130 DI 130 10130 nvoFGRAMnOBP_XXX SNVT_switch
Pushbutton Pressed
AB[8].2 Fuel 3 Actuator #1 Manual Override BI 131 DI 131 10131 nvoFl3A1MOBP_XXX SNVT_switch
Pushbutton Pressed
AB[8].3 Fuel 3 Actuator #2 Manual Override BI 132 DI 132 10132 nvoFl3A2MOBP_XXX SNVT_switch
Pushbutton Pressed
AB[8].4 Communication from BMS Failed BI 133 DI 133 10133 nvoComBMSFld_XXX SNVT_switch
AB[8].5 Combustion Air Pressure High BI 134 DI 134 10134 nvoLoO2Shdn_XXX SNVT_switch
AB[8].6 Water Flow Low BI 135 DI 135 10135 nvoAB_8_6_XXX SNVT_switch
AB[8].7 Water Level Signal Failed BI 136 DI 136 10136 nvoAB_8_7_XXX SNVT_switch
AB[8].8 Remote Setpoint Signal Failed BI 137 DI 137 10137 nvoAB_8_8_XXX SNVT_switch
AB[8].9 Low O2 Shutdown BI 138 DI 138 10138 nvoAB_8_9_XXX SNVT_switch
AB[8].10 Air Actuator Fault BI 139 DI 139 10139 nvoAB_8_10_XXX SNVT_switch
AB[8].11 Fuel 1 Actuator 1 Fault BI 140 DI 140 10140 nvoAB_8_11_XXX SNVT_switch
AB[8].15 FGR Actuator Fault BI 144 DI 144 10144 nvoAB_8_15_XXX SNVT_switch
AB[9].0 Fuel 2 Actuator 2 Position Deviation BI 145 DI 145 10145 nvoAB_9_0_XXX SNVT_switch
AB[9].1 Fuel 2 Actuator 2 Feedback Low BI 146 DI 146 10146 nvoAB_9_1_XXX SNVT_switch
Part No. 750-342 A-3

AB[9].2 Fuel 2 Actuator 2 Feedback High BI 147 DI 147 10147 nvoAB_9_2_XXX SNVT_switch
AB[9].3 Fuel 2 Actuator 2 Manual PB Pressed BI 148 DI 148 10148 nvoAB_9_3_XXX SNVT_switch
AB[9].4 VFD Feedback Low BI 149 DI 149 10149 nvoAB_9_4_XXX SNVT_switch
AB[9].5 VFD Feedback High BI 150 DI 150 10150 nvoAB_9_5_XXX SNVT_switch
AB[9].6 Master PIDE Instruction Fault BI 151 DI 151 10151 nvoAB_9_6_XXX SNVT_switch
AB[9].7 FGEN Fault BI 152 DI 152 10152 nvoAB_9_7_XXX SNVT_switch
AB[9].8 Outdoor Temp Sensor Failed BI 153 DI 153 10153 nvoAB_9_8_XXX SNVT_switch
AB[9].9 Combustion Air Temp Sensor Failed BI 154 DI 154 10154 nvoAB_9_9_XXX SNVT_switch
AB[9].10 Yokogawa O2 Sensor Fault BI 155 DI 155 10155 nvoAB_9_10_XXX SNVT_switch
AB[9].11 Mix O2 Sensor Calibration Fail BI 156 DI 156 10156 nvoAB_9_11_XXX SNVT_switch
AB[9].12 Mix O2 Enable BI 157 DI 157 10157 nvoAB_9_12_XXX SNVT_switch
AB[9].13 Air Actuator Not at Purge BI 158 DI 158 10158 nvoAB_9_13_XXX SNVT_switch
AB[9].14 VFD Not at Purge BI 159 DI 159 10159 nvoAB_9_14_XXX SNVT_switch
AB[9].15 Hawk 1000 system BI 160 DI 160 10160 nvoAB_9_15_XXX SNVT_switch
AB[10].0 Hawk 4500 - Increase MSG Size of Bool BI 161 DI 161 10161
to 15
AB[10].1 Stack Temp Econ Out Sensor Failed BI 162 DI 162 10162
AB[10].2 Econ In Water Temp Sensor Failed BI 163 DI 163 10163
AB[10].3 Fuel 3 Actuator 1 Fault BI 164 DI 164 10164
AB[10].4 Fuel 3 Actuator 2 Position Deviation BI 165 DI 165 10165
AB[10].5 Fuel 3 Actuator 2 Feedback Low BI 166 DI 166 10166
AB[10].6 Fuel 3 Actuator 2 Feedback High BI 167 DI 167 10167
AB[10].7 Fuel 3 Actuator 2 Fault BI 168 DI 168 10168
AB[10].8 Fuel 3 Actuator 1 Modbus Comm Error BI 169 DI 169 10169
AB[10].11 Return Temp Sensor Failed BI 172 DI 172 10172
AB[10].12 Water Shell Temp Sensor Failed BI 173 DI 173 10173
AB[10].13 Feedwater/Econ Out Temp Sensor Failed BI 174 DI 174 10174
AB[10].14 Feedwater Level Control Option Selected BI 175 DI 175 10175
AB[10].15 BI 176 DI 176 10176
AB[11].0 Slot8 Ch0 Bad Quality BI 177 DI 177 10177
AB[11].1 Slot8 Ch0 Low Alarm BI 178 DI 178 10178
AB[11].2 Slot8 Ch0 High Alarm BI 179 DI 179 10179
AB[11].6 Slot8 Ch2 Bad Quality/Mix O2 Signal Fail BI 183 DI 183 10183
AB[11].15 Spare BI 192 DI 192 10192
A-4 Part No. 750-342


AB[12].9 VFD EtherNet Comm Error BI 202 DI 202 10202
AB[12].10 Slot 8 Ch 4 Analog Input Selected BI 203 DI 203 10203
AB[12].14 BI 207 DI 207 10207
AB[12].15 BI 208 DI 208 10208
AB[13].0 Air Actuator 2 Position Deviation BI 209 DI 209 10209
AB[13].1 Air Actuator 2 Feedback Low BI 210 DI 210 10210
AB[13].2 Air Actuator 2 Feedback High BI 211 DI 211 10211
AB[13].3 Air Actuator 2 Modbus Comm Error (Node BI 212 DI 212 10212
4)
AB[13].4 Air Actuator 2 Manual PB Pressed BI 213 DI 213 10213
AB[13].5 Air Actuator 2 Fault BI 214 DI 214 10214
AB[13].6 Air Actuator 2 Not At Purge BI 215 DI 215 10215
AB[13].7 Air Actuator 2 Not At Lightoff BI 216 DI 216 10216
AB[13].8 Air Actuator Not At Lightoff BI 217 DI 217 10217
AB[13].9 Fuel Actuator 1 Not At Lightoff BI 218 DI 218 10218
AB[13].10 Fuel Actuator 2 Not At Lightoff BI 219 DI 219 10219
AB[13].11 FGR Actuator Not At Lightoff BI 220 DI 220 10220
AB[13].12 VFD Not At Lightoff BI 221 DI 221 10221
AB[13].13 BI 222 DI 222 10222
AB[13].14 BI 223 DI 223 10223
AB[13].15 BI 224 DI 224 10224
AB[14].0 NOx Analzer Present BI 225 DI 225 10225
AB[14].1 NOx Trim Enabled BI 226 DI 226 10226
AB[14].2 NOx Sensor Calibration Failed Alarm BI 227 DI 227 10227
AB[14].3 NOx Sensor Comms Not OK BI 228 DI 228 10228
AB[14].4 BI 229 DI 229 10229
AB[14].5 BI 230 DI 230 10230
AB[14].6 BI 231 DI 231 10231
AB[14].7 BI 232 DI 232 10232
AB[14].8 BI 233 DI 233 10233
AB[14].9 BI 234 DI 234 10234
AB[14].10 BI 235 DI 235 10235
AB[14].11 BI 236 DI 236 10236
AB[14].12 BI 237 DI 237 10237
AB[14].13 BI 238 DI 238 10238
AB[14].14 BI 239 DI 239 10239
AB[14].15 BI 240 DI 240 10240
AR[0] Flame Strength Honeywell AI 1 AI 1 30001 nvoFlmStrHny_XXX SNVT_count_f
AR[1] Combustion Air Fan Speed AI 2 AI 2 30003 nvoCmArFnSpd_XXX SNVT_count_f
AR[2] AR[2] AI 3 AI 3 30005 nvoAR_2__XXX SNVT_count_f
AR[3] Boiler Efficiency AI 4 AI 4 30007 nvoBlrEff_XXX SNVT_lev_percent
AR[4] Firing Rate AI 5 AI 5 30009 nvoFirRat_XXX SNVT_lev_percent
AR[5] O2 Level AI 6 AI 6 30011 nvoO2Lvl_XXX SNVT_lev_percent
AR[6] SP Steam Pressure/Water Temp AI 7 AI 7 30013 nvoSPStPWtTp_XXX SNVT_count_f
AR[7] Water Level AI 8 AI 8 30015 nvoWtrLvl_XXX SNVT_press_f
AR[8] Steam Pressure or Hot Water Temp AI 9 AI 9 30017 nvoStPrHWTmp_XXX SNVT_count_f
AR[9] AR[9] AI 10 AI 10 30019 nvoAR_9_XXX SNVT_count_f
Part No. 750-342 A-5

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

AR[11] Combustion Air Temp AI 12 AI 12 30023 nvoComAirTmp_XXX SNVT_temp_p
AR[12] Water Temp Shell/Outdoor Temp AI 13 AI 13 30025 nvoWtTpShl_XXX SNVT_temp_p
AR[13] Feedwater Temp/Econ Water Out Temp AI 14 AI 14 30027 nvoFdWtTp_XXX SNVT_temp_p
AR[14] Stack Temp After Econ/Return HW AI 15 AI 15 30029 nvoStkTmpEco_XXX SNVT_temp_p
AR[15] Economizer Water In Temp AI 16 AI 16 30031 nvoEcWtInTmp_XXX SNVT_temp_p
AR[16] AI Slot8Ch0 Value/2Stg Econ Temp IN AI 17 AI 17 30033 nvoAISlCh0Vl_XXX SNVT_count_f
AR[17] AI Slot8Ch1 Value/2Stg Econ Temp OUT AI 18 AI 18 30035 nvoAISlCh1Vl_XXX SNVT_count_f
AR[18] AI Slot8 Ch2 Value (EU) AI 19 AI 19 30037 nvoAISlCh2Vl_XXX SNVT_count_f
AR[19] AI Slot8 Ch3 Value (EU) AI 20 AI 20 30039 nvoAISlCh3Vl_XXX SNVT_count_f
AR[20] Safety Valve Setting or Max Water Temp AI 21 AI 21 30041 nvoSftVlvSet_XXX SNVT_count_f
AR[21] Header Pressure or Temp 2 Boiler LL AI 22 AI 22 30043 nvoHdPrTpBLL_XXX SNVT_count_f
AR[22] SP 2 Boiler LL AI 23 AI 23 30045 nvoSP2BlrLL_XXX SNVT_count_f
AR[23] Boiler Off Point AI 24 AI 24 30047 nvoBlrOffPt_XXX SNVT_count_f
AR[24] Boiler On Point AI 25 AI 25 30049 nvoBlrOnPt_XXX SNVT_count_f
AR[25] Condensate Return Valve Output AI 26 AI 26 30051 nvoCdRtVOtCm_XXX SNVT_lev_percent
Command
AR[26] Makeup Bypass Valve Output Command AI 27 AI 27 30053 nvoMkByVOtCm_XXX SNVT_lev_percent
AR[27] Slot8 Ch0 FLo Total AI 28 AI 28 30055 nvoSlC0FlTo_XXX SNVT_count_f
AI[0] Burner Control Status Line 1 Honeywell AI 52 AI 52 30102 nvoBSt1Hnywl_XXX SNVT_count_f
AI[1] Burner Control Status Line 2 Honeywell AI 53 AI 53 30103 nvoBSt2Hnywl_XXX SNVT_count_f
AI[2] Burner Control Status Line 1 Fireye AI 54 AI 54 30104 nvoBSt1Freye_XXX SNVT_count_f
AI[3] Burner Control Status Line 2 Fireye AI 55 AI 55 30105 nvoBSt2Freye_XXX SNVT_count_f
AI[4] Flame Signal Fireye AI 56 AI 56 30106 nvoFlSgFrey_XXX SNVT_count_f
AI[5] Fuel 1Type AI 57 AI 57 30107 nvoFl1Type_XXX SNVT_count_f
AI[6] Fuel 2 Type AI 58 AI 58 30108 nvoFl2Type_XXX SNVT_count_f
AI[7] Fuel 3 Type AI 59 AI 59 30109 nvoFl3Type_XXX SNVT_count_f
AI[9] Elapsed Time (First 16 Bits) AI 61 AI 61 30111 nvoElpTm1_XXX SNVT_time_hour
AI[10] Elapsed Time (Second 16 Bits) AI 62 AI 62 30112 nvoElpTm2_XXX SNVT_time_hour
AI[11] Number Of Cycles (First 16 Bits) AI 63 AI 63 30113 nvoNumCyc1_XXX SNVT_count_f
AI[12] Number Of Cycles (Second 16 Bits) AI 64 AI 64 30114 nvoNumCyc2_XXX SNVT_count_f
A-6 Part No. 750-342

AI[13] AI[13] AI 65 AI 65 30115 nvoAI_13_XXX SNVT_count_f

AD[0] Elapsed Time AI 82 AI 82 30132 nvoElapTim_XXX SNVT_time_hour
AD[1] Number Of Cycles AI 83 AI 83 30134 nvoNumCyc_XXX SNVT_count_f
AWB[0].0 Heart Beat From BMS BV 1 DO 1 00001 nvoHtBtFrBMS_XXX SNVT_switch
AWB[0].1 Rem Start From BMS BV 2 DO 2 00002 nvoRmStFrBMS_XXX SNVT_switch
AWB[0].2 AWB[0]2 BV 3 DO 3 00003 nvoAWB_0_2_XXX SNVT_switch
AWR[0] Rem Op SP Boiler AV 1 AO 1 40001 nvoRmOpSPBlr_XXX SNVT_count_f
Part No. 750-342 A-7

AWR[1] Rem Firing Rate AV 2 AO 2 40003 nvoRemFirRat_XXX SNVT_lev_percent

AWR[2] Rem Op SP 2 boiler Lead/Lag AV 3 AO 3 40005 nvoRmOSP2BLL_XXX SNVT_count_f
AWR[3] AWR[3] AV 4 AO 4 40007 nvoAWR_3_XXX SNVT_count_f
A-8 Part No. 750-342

Hawk 4000 APPENDIX B
APPENDIX B LOADING A PLC PROGRAM
Loading a Hawk PLC program from an SD card to an L33ER or L24ER processor.

Required Hardware:
SD card: Every PLC processor should come with an SD
card from Rockwell Automation.
SD Card Reader
Laptop Computer
1.If the PLC program file is in .zip format it must be
extracted.
2.Use your computer SD card reader or connect an external
SD card reader to the computer.
3.Select the Logix .zip file and Right mouse click.
4.Select Open with WinZip (or another extraction program)
5.From WinZip select Extract.
6.Navigate to the location of the SD card that will be used to transfer the Logix folder to the PLC. Select
Extract.
Part No. 750-342 B-1

APPENDIX B Hawk 4000
7.Close the WinZip program.

8.The Logix folder should now be extracted to the SD card. The logix folder must be at the root directory of
the SD card. No other files should be present on the SD card. Use Windows Explorer to verify the Logix folder
on the SD card.
9.Use the Remove Hardware tool to safely eject the SD card from the computer.
B-2 Part No. 750-342

Hawk 4000 APPENDIX B
10. Install the SD card into the PLC SD card slot. The PLC switch should be in REM.
11.Cycle power to the PLC.

12.The transfer from the SD card to the PLC processor will begin. Please be
patient while the installation is in progress, the whole process from power up
to completion may take up to 3 Minutes. Prematurely ending the SD card load
process may render the plc unuseable!
13.During the transfer process the OK Led on the PLC will be solid RED. The
SD Led will begin to flash GREEN indicating that the PLC is reading from the
SD card. Upon completion, the RUN and OK Led's should be solid GREEN. If
run Led is NOT Solid Green put PLC switch to RUN.
14.Remove the SD card from the PLC SD card slot.
15.If the SD card has come from the factory or if the program was taken from
the CB Portal, loading from the SD card will install PLC firmware, the PLC
program, and set the IP address of the PLC to 192.168.1.101.
Part No. 750-342 B-3

e-mail: info@cleaverbrooks.com
Web Address: http://www.cleaverbrooks.com

750-342 Hawk 4000 Jan 2016 PDF

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Hawk 4000

Manual Part No. 750-342

APPENDIX A HAWK 4000 MASTER TAG LIST

APPENDIX B LOADING A PLC PROGRAM

Figure 1-1. Boiler Overview Screen

1. (Slot 0) - PLC L33ER

Figure 1-2. Typical Panel Layout

1-2 Part No. 750-342

1.2 System Description

Level Master - 750-281

Part No. 750-342 1-3

1.3 Hawk 4000 System Features

1.3.1 New features 2016

HAWK 4000 previous versions HAWK 4000 new

1-4 Part No. 750-342

1.4 Safety Provisions and Diagnostics

Figure 1-3. FSG / Burner Control screen

1.4.2 Boiler Controls

Part No. 750-342 1-5

1.5 Inputs and Outputs

Address Name Address Name Address Name Address Name

1-6 Part No. 750-342

Figure 2-1. Hawk 4000 PLC Rack

2.2 PLC Rack Components

2-2 Part No. 750-342

DISCRETE and ANALOG Signal Types

2.3 Human-Machine Interface (HMI)

Figure 2-2. Hawk 4000 HMI

Part No. 750-342 2-3

Serial (not used

USB EtherNet 120VAC power

Figure 2-3. Hawk 4000 HMI Logic Module connections

2-4 Part No. 750-342

Figure 2-5. L33ER PLC Communication Ports

2.5 Sensor Inputs

Sensor System Standard Optional

2.5.1 Steam Systems:

Part No. 750-342 2-5

2.5.2 Hot Water systems:

2-6 Part No. 750-342

3.1 Control Panel

Figure 3-1. DIN rail latches

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

3-2 Part No. 750-342

3.1.2 Panel and Field Wiring Terminations

3.1.3 SM2 Module DIP Switch

Figure 3-3. SM2 module DIP switch setting

3.1.4 Burner Control Modbus Address and Baud Rate - CB780E

Press the two ENTER buttons at the same time.

Part No. 750-342 3-3

Press ENTER buttons at the same time.

Press down arrow twice.

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

Press down arrow key to save changes.

Press down arrow key until MB BAUD is displayed.

3-4 Part No. 750-342

Press ENTER buttons at the same time.

Press down arrow to select.

Press down arrow key to save changes.

Press ENTER buttons at the same time.

Part No. 750-342 3-5

Press upper arrow key to exit.

3.1.5 Burner Control Modbus Address and Baud Rate - CB120E