Hawk 1000

Boiler Control

Operation Manual

750-366
01/2019
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 the attendant of any responsibility. Such features merely
free him of certain repetitive chores and give him more time to devote to the proper upkeep of equipment.

It is solely the operator’s responsibility to properly operate and maintain the equipment. No amount of written instruc-
tions can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of
the responsibility for proper operation. On the other hand, a thorough understanding of this manual is required before
attempting to operate, maintain, service, or repair this equipment.
Operating controls will normally function for long periods of time and we have found that some operators become lax in
their daily or monthly testing, assuming that normal operation will continue indefinitely. Malfunctions of controls lead to
uneconomical operation and damage and, in most cases, these conditions can be traced directly to carelessness and
deficiencies in testing and maintenance.

The operation of this equipment by the owner and his operating personnel must comply with all requirements or regula-
tions of his insurance company and/or other authority having jurisdiction. In the event of any conflict or inconsistency
between such requirements and the warnings or instructions contained herein, please contact Cleaver-Brooks before pro-
ceeding.
 Cleaver-Brooks
HAWK 1000
Boiler Control

Operation Manual

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

Manual Part No. 750-366

01/2019
 CONTENTS
Section 1
General
Introduction ............................................................................................... 1-2
System Description ..................................................................................... 1-3
Hawk 1000 System Features ....................................................................... 1-4
Program Numbers ....................................................................................... 1-4
Safety Provisions and Diagnostics ................................................................. 1-5
Inputs and Outputs...................................................................................... 1-6

Section 2
System Components
Overview ................................................................................................... 2-2
Controller .................................................................................................. 2-2
Human-Machine Interface (HMI) ................................................................. 2-3
Communications ........................................................................................ 2-4
Sensor Inputs ............................................................................................ 2-6

Section 3
Hardware Checkout
Control Panel .............................................................................................. 3-2
Modbus Actuators ...................................................................................... 3-7

Section 4
System Configuration
Introduction ............................................................................................. 4-2
Main Menu .............................................................................................. 4-3
Boiler Overview ........................................................................................ 4-4
System Configuration ................................................................................ 4-5
Email Setup.............................................................................................. 4-25
PanelView Plus Setup ................................................................................ 4-26
Remote Monitoring .................................................................................... 4-34

Section 5
Commissioning
Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Setting Combustion - Parallel Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Setting Combustion - Low/High/Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Alarms and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Drive Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Ethernet Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Two Boiler Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Thermal Shock Routine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Section 6
Diagnostics and Troubleshooting
System Monitoring and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
PLC Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Section 7
Parts
Hawk 1000 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

APPENDIX A Tag List

APPENDIX B Loading a PLC Program
 Section 1
General
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hawk 1000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Program Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Provisions and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Burner Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

www.cleaverbrooks.com
Section 1 — General Hawk 1000

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

Figure 1-1. Boiler Overview Screen

Figure 1-2. Typical Panel Layout

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Hawk 1000 Section 1 — General

1.2 System Description

The HAWK 1000 Boiler Control System provides boiler firing rate control to maintain steam pressure (or hot
water supply temperature) on set point. Final control element(s) are modulated via Modbus communications
network to insure that the optimum fuel/ air ratio is maintained throughout the firing range.
The Hawk 1000 supports two fuel types. Each fuel type can be fired in one of three possible methods: single-
point combustion, parallel combustion, and LOW-HIGH-LOW (fuel 2 only). In parallel systems, the Hawk
1000 can also control a flue gas recirculation (FGR) damper.
The Hawk 1000 can be monitored by Building/ Plant Automation Systems via an optional Cleaver-Brooks
ProtoNode protocol translator. EtherNet/ Internet communication also enables remote monitoring of the Hawk
1000 Boiler Control System. (Additional software and/or hardware required).
The HAWK 1000 may be used on most types of steam and hot water boilers, including firetube, industrial
watertube, and commercial watertube. In addition to installation on new boilers, the HAWK 1000 can be
added as a retrofit to existing boilers. Call your local authorized Cleaver-Brooks representative for details.
Consult the following Cleaver-Brooks manuals for supplementary operating and maintenance information
regarding specific system options:

Level Master - 750-281

ProtoNode Protocol Translator - 750-426
CB120E Burner Control - 750-264
CB780E Burner Control - 750-234
Variable Speed Drives - 750-198
O2 Trim - 750-224
Master Panel 8 - 750-375
Master Panel 4 - 750-383

Part No. 750-366 1-3

Section 1 — General Hawk 1000

1.3 Hawk 1000 System Features

• Burner Control controls burner start and shutdown sequencing and flame and interlock monitoring
• Compatible with CB780E and CB120E Burner Controls and Flame Scanners
• Boiler Control monitors and displays connected boiler parameters (operating pressure or temperature, stack
temperature, shell water temperature, O2% etc.)
• 6” color touch/keypad Human Machine Interface (HMI)
• Optimized boiler firing rate control
• Alarm/Fault Indication and History -- first out annunciation with time stamp and displayed in order of fault occurrence
• Dual set point capability
• Thermal shock protection (includes warm-up routine, low fire hold & hot stand-by operation)
• Available input for any ONE of the following: remote modulation, remote set point, or Level Master water level interface
• Available input for any ONE of the following: water temp (Steam)
• Return Temp or Outdoor reset (hot water boilers)
• Remote Modulation by communications (EtherNet)
• Remote Set Point by communications (EtherNet)
• Boiler efficiency calculation
• Assured Low Fire Cut Off
• External Interlock with auxiliary devices (fresh air damper/louvers, circulating pumps, etc.)
• High stack temperature alarm and shutdown
• Built-in two-boiler lead/lag capability
• EtherNet communications
• Three firing modes: Single-point, parallel, or LOW-HIGH-LOW on Fuel 2
• Revert to Pilot control function (requires CB120E burner control)
• Supports control of a flue gas recirculation (FGR) damper
• Supports the control of a 2nd gaseous fuel actuator (Both Gaseous Fuels)
• OPC server software for building/plant automation system interface
• Remote monitoring software
• O2 monitoring and O2 trim (Option)
• Variable Speed Drive on combustion air fan (with bypass) (Option)
• Combustion Air Temperature Monitoring (Option)
• Email and text messaging for alarms/faults
• Force Hot Standby by HMI

1.4 Program Numbers

Hawk 1000 PLC and HMI programs can be identified by the following program numbers:
PLC Standard Program: 98500509_001_xxx
PLC Standard Metric Program: 98500509_001_xxx_Metric
6” HMI Program: 98500670_xxx
6” HMI Metric Program: 98500695_xxx

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Hawk 1000 Section 1 — General

1.5 Safety Provisions and Diagnostics

1.5.1 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

1.5.2 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. 750-366 1-5

Section 1 — General Hawk 1000

1.6 Inputs and Outputs

Processor 1769-L24ER-QBFC1B - Slot 0
Embedded I/O - Slot 1-3
Dig IN Dig OUT Anlg IN Anlg Out
High Limit Control I1/0
ALWCO I1/1
Low Fuel 1 Pressure/Low Oil Temp I1/2
High Fuel 1 Pressure/High Oil Temp I1/3
Low Fuel 2 Pressure I1/4
High Fuel 2 Pressure I1/5
Oil Drawer Switch I1/6
Atomizing Air Pressure Low I1/7
Combustion Air Pressure Low I1/8
High Water (ST) or Flow Sw. (HW) I1/9
VSD Bypass I1/10
Combustion Air Pressure High I1/11
Spare I1/12
Auxiliary Alarm 1 I1/13
Auxiliary Alarm 2 I1/14
Auxiliary Alarm 3 I1/15
2 Boiler Lead Lag Master Start Slave Boiler O1/0
Ready for Lead/Lag O1/1
To Stand Alone Draft O1/2
Spare(s) O1/3-O1/15
Steam Pres (ST) / Supply Temp (HW) I2/0
Stack Temp I2/1
Water Temp (ST) / Outdoor Temp (HW) / Return Temp (HW) I2/2
Water Level (ST) / Rem Mod / Rem Set Point I2/3
VSDControl O2/0
Firing Rate or Two Boiler Llag Control O2/1
High Speed Counter (NOT USED) Slot 3

Slot 4 Slot 5 Slot 6 Slot 7

SM2 I5/0 Blower Terminal O6/0 Recycle Limit (RLR) I7/0 VSD Feedback
Modbus I5/1 Purge O6/1 Start Ext. Device (FAD) I7/1 O2 Signal
Module I5/2 O2 Analyzer Status (Yokogawa) O6/2 Non-Recycle Limit (NRLR) I7/2 Comb Air Temp
I5/3 VSD Status O6/3 Prove Low Fire I7/3 Common Header Press (ST) Temp (HW)
I5/4 Force to Low Fire O6/4 Revert To Pilot (Fireye CB120E only)
Slot 4
I5/5 Ready To Start/ Limits Closed O6/5 Prove High Fire / Open High Fire Oil Valve 2
I5/6 Ext. Device Start Interlock (FAD) O6/6 Alarm Bell
I5/7 ALFCO O6/7 Open High Fire Oil Valve 1
I5/8 Pilot Terminal
I5/9 Main Fuel Terminal
I5/10 Fuel 1 Selected
I5/11 Fuel 2 Selected
I5/12 Burner Control Alarm Terminal
I5/13 Low Water Alarm
I5/14 Slave Boiler Available/ Sel Rem Mod / Sel Set Point
I5/15 Burner Switch

1-6 Part No. 750-366

 Section 2
System Components
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Human-Machine Interface (HMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Sensor Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Steam Systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Hot Water systems: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

www.cleaverbrooks.com
Section 2 — System Components Hawk 1000

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

1a 1b 2 3 4 5

6 7 8
9

Figure 2-1. Hawk 1000 Panel

1. Base Unit
1a. L24ER Programmable Logic Controller (PLC)
1b. Embedded I/O
2. SM2 Modbus Communications Module
3. Digital Inputs
4. Digital Outputs
5. Analog Inputs (optional)
6. Burner Control
7. Power supplies
8. Circuit breakers, relays, fuses, etc.
9. ALWCO control
The HAWK 1000 Boiler Controller is factory pre-programmed to work with most Cleaver-Brooks firetube and
watertube boilers, yet allows easy configuration for specific boiler applications. The Boiler Controller program
logic is password secured, ensuring tamper- proof controller operation. The Touch Screen HMI provides user-
friendly access to firing rate control functions, boiler diagnostics and alarm history, as well as connected
operating parameters. Burner management is handled by the proven CB780E or optional CB120E Flame
Safety Control.

2.2 Base Unit

The Base Unit consists of the Processor (CPU) which holds the program logic and configuration for the boiler
controller and embedded I/O modules which consist of discrete inputs, discrete outputs, and analog inputs.
The program logic is password-secured at the factory.
The SM2 module handles the Modbus communications between the PLC and other devices.

2-2 Part No. 750-366

Hawk 1000 Section 2 — System Components

The Module Power Supply powers the Base Unit and the I/O modules. The remainder of the PLC rack is for
the discrete input and output modules, and for analog input module (optional).
I/O modules are used to send and receive control and communication signals to/from other parts of the system.

Slot Module
0 1769-L24ER-QBFC1B Processor
1 Embedded Discrete Inputs/Outputs BASE
2 Embedded Analog Inputs/Outputs UNIT
3 Embedded High Speed Counter
4 SM2 Modbus Module
5 Digital Input Module
6 Relay Output Module
7 Analog Input Module (4 ch. - optional)

A Right End Cap Terminator is required to complete the modular communication bus. It attaches to the right
side of the last module in the rack.
An optional analog input module can be added to the PLC to provide additional functionality.

DISCRETE and ANALOG Signal Types

Discrete inputs/outputs are used for signals taking on only one of two possible states (on/off, open/
close, etc.). The input state is represented by a bit (0 or 1) in the control logic. Example:
Boiler Ready (yes/no)
Analog signals can assume almost infinite values within the fixed analog input/ output current range
of 4-20 mA. The Hawk 1000 PLC converts this current value to a range in engineering units. Example:
Steam Pressure (0-150 PSI)

NOTE: The PLC program expects each device to be in a specific slot location. The HAWK 1000 controls
will not function unless all devices are properly installed and configured.

2.3 Human-Machine Interface

(HMI) BATTERY

The HMI displays numerous boiler

parameters at a glance and provides SD CARD
SLOT
easy menu navigation for configuring
system parameters, setting of USB
DEVICE PORT
combustion, monitoring the boiler USB
HOST PORT
processes, and managing and
annunciating system alarms.
The HMI communicates with the PLC
via Ethernet and is powered by a
24VDC din-rail mounted power supply.
ETHERNET

POWER
Figure 2-2. PanelView connections

Part No. 750-366 2-3

Section 2 — System Components Hawk 1000

Figure 2-3. Firing Rate screen

2.4 Communications
2.4.1 Modbus
Modbus is an open serial protocol used by the HAWK 1000 system for sending and receiving control
commands, position data, and diagnostic data between the PLC and attached devices. Modbus
communications are managed by the SM2 module located to the right of the base unit in slot 4.
HAWK 1000 devices that communicate using Modbus include the burner flame safety control and the fuel, air,
and FGR actuators. The Modbus communication network allows burner control system status and fault
information to be transmitted to the PLC and displayed on the HMI screen, and in addition is used for actuator
control, feedback, and fault information.

Figure 2-4. SM2 Modbus Module

2-4 Part No. 750-366

Hawk 1000 Section 2 — System Components

2.4.2 Ethernet
The HAWK 1000 uses Ethernet for several communication functions:
• Communication between the PLC and HMI. The Ethernet cable connecting the PLC and HMI can be either
a straight through or a crossover type.
• Connection of the boiler control system to an existing infrastructure, i.e. plant Local Area Network (LAN)
• Integration with a Building/Plant Automation System (BAS)
• Remote monitoring of boiler control system via the customer's Wide Area Network (WAN) or via the Internet
• Connection of a laptop for diagnostics
• Email or texting of boiler alarms to plant or service personnel
Ethernet/IP is also used for control functions. Individual boiler controllers may be networked to facilitate lead/lag
control, with a single BAS interface for multiple boiler systems.
• Networking multiple boiler controllers with a single BAS interface
• Writing remote setpoint or remote start/stop of boiler
• Writing remote firing rate of boiler
• Networking two boiler controllers with Cleaver Brooks two boiler lead lag
• Networking multiple boiler controllers with a Cleaver-Brooks Master Panel

2.4.3 USB
USB communications are used to connect a laptop computer 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.

PORT 1 L24ER 0 1 2 3 4 5 6 7 A0 B0 Z0

SOURCE

IN
24VDC
0 1 2 3 4 5 6 7 A0 B0 Z0

SINK\

INPUT
DC

HIGH SPEED
QBFC1B A1 B1 Z1

COUNTER
8 9 10 11 12 13 14 15

SOURCE

IN
24VDC
SINK\

INPUT
DC

HIGH SPEED
A1 B1 Z1

COUNTER
8 9 10 11 12 13 14 15

OUT
OUTPUT
SOURCE
24VDC

DC
0 1 2 3 4 5 6 7 0 2 FUSE

OUT
OUTPUT
SOURCE
24VDC

DC
0 1 2 3 4 5 6 7 0 2 FUSE
8 9 10 11 12 13 14 15 1 3 OK
8 9 10 11 12 13 14 15 1 3 OK

DC IN HSC

00 08 A0+ A0-

01 09 B0+ B0-

PORT 2 02 10

03 11
Z0+ Z0-

A1+ A1-

04 12 B1+ B1-

05 13 Z1+ Z1-

06 14 +V +V
OUT OUT
07 15 0 2
COM COM OUT 0UT
0 1 1 3
NC NC COM COM
V V
+V +V in in
0+ 2+

USB 00 08

01 09
I
in
0+
V/I
in
0-
in
2+
I

V/I
in
2-

PORT 02 10

03 11
CJC
+
CJC
-
V
in
3+
I
in
3+
V V/I
04 12 in in
1+ 3-
00:00:BC:2E:69:F6 05 13
I
in
V/I
in
1+ 1-
V V
06 14 OUT OUT
0+ 1+
I I
07 15 OUT in
0+ 1+
COM COM COM COM
0 1
DC OUT ANALOG

+24VDC
+24VDC COM
COM FG
FG

Ethernet ports (bottom of Base Unit)

Figure 2-5. L24ER Communication Ports

Part No. 750-366 2-5

Section 2 — System Components Hawk 1000

2.5 Sensor Inputs

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

Sensor System Standard Optional

Steam Pressure ST Yes
Stack Temperature ST & HW Yes
Water Temperature ST Yes
Water Level ST Yes
Supply Temperature HW Yes
Outdoor Temperature HW Yes
Return Temperature HW Yes
Comb. Air Temperature ST & HW Yes
Steam Header Pressure for Two Boiler Lead Lag Master ST Yes
Header Water Temp for Two Boiler Lead Lag Master HW Yes

All systems use RTDs with a transmitter to produce 4-20mA output for temperature detection.

2.5.1 Steam Systems:

Steam Pressure is the primary sensor input to the HAWK 1000 Controller in a Steam System. It transmits a
4-20mA process variable signal to the Controller that is used to control Firing Rate and the Operating Limit
Control.
Stack Flue Gas Temperature is used for High Stack Temperature alarms and shutdown. It is also used in the
boiler efficiency calculation.
Water Temperature (mandatory on steam boilers) measures boiler-shell water temperature and is used for
thermal shock protection and hot standby control on steam boilers. The standard location for the thermowell is
a 1/2” NPT coupling at the right-hand side center-line of the boiler shell. If this location is not available, an
unused feedwater connection may be used.
Water Level sensor is OPTIONAL on steam boilers, but must be a CB Level Master.
Steam Header Pressure sensor is optional on steam boilers configured as two boiler Lead Lag master.

2.5.2 Hot Water systems:

Supply Temperature is the primary sensor input to the HAWK 1000 Controller in a Hot Water system. It
transmits a 4-20mA process variable signal to the Controller that is used to control Firing Rate and the
Operating Limit Control.
Outdoor Temperature is used in Hot Water Systems with the Outdoor Temperature Reset Option.
Return Temperature is used in Hot Water Systems with the Return Temperature option and is monitor only.
Header Water Temperature sensor is optional on steam boilers configured as two boiler Lead Lag master.

NOTE: The Outdoor Temperature and Return Temperature sensors use the same input. One or the other can
be used with the Hawk 1000, but not both.

2-6 Part No. 750-366

 Section 3
Hardware Checkout
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
DIN Rail Latch and Expansion I/O Module Locking Levers . . . . . . 3-2
Panel and Field Wiring Terminations . . . . . . . . . . . . . . . . . . . . . 3-3
SM2 Module DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Burner Control Modbus Address and Baud Rate - CB780E . . . . . 3-4
Burner Control Modbus Address and Baud Rate - CB120E . . . . . 3-6
PLC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Modbus 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

www.cleaverbrooks.com
Section 3 — Hardware Checkout Hawk 1000

! Important
The base unit and expansion modules do not support removal and insertion under power. While the PLC
system is under power, any break in the connection between the power supply and the base unit (i.e.
removing the power supply, base unit, or an expansion module) will clear processor memory including the
user program. Ensure that the electrical power is OFF before removing or inserting any PLC device.

3.1 Control Panel

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.

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3.1.2 Panel and Field Wiring Terminations

Check that all factory wiring connections are tight and that field wiring terminations are completed and secure.

Figure 3-3. Check all wiring and connections

3.1.3 SM2 Module DIP Switch

Verify that the SM2 Module DIP switch setting is as shown below (the top switch is to the left, the bottom
switch is to the right).

DIP switch
settings: Top L,
Bottom R

Figure 3-4. SM2 module DIP switch setting

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3.1.4 Burner Control Modbus Address and Baud Rate - CB780E

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

Press the two ENTER buttons at the same time.

Press down arrow until MB ADDRESS is displayed.

Press ENTER buttons at the same time.

Press down arrow twice.

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

Press ENTER buttons at the same time.

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Press down arrow key to save changes.

Press down arrow key until MB BAUD is displayed.

Press ENTER buttons at the same time.

Press down arrow to select.

Using up or down arrow key select 9600.
Press ENTER keys at the same time.

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Section 3 — Hardware Checkout Hawk 1000

Press down arrow key to save changes.

Press ENTER buttons at the same time.

Press upper arrow key to exit.

3.1.5 Burner Control Modbus Address and Baud Rate - CB120E

The CB120E has built-in Modbus capability; for proper communications the ModBus baud rate and node
address need to be correctly set. To check the settings, the CB120E must be powered.
Press the <BACK> or <NEXT> key on the CB120E display until the screen displays PROGRAM SETUP>.

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Press the <MODE> then the <NEXT> key until the screen displays BAUD RATE.
Press <MDFY> and use the <BACK> or <NEXT> key to change to 4800. Press <MDFY> to save.
Press the <NEXT> key until UNIT ADDRESS # is displayed. To change the unit address, use the <BACK>
or <NEXT> key to change to 5. Press <MDFY> to save.
Press <MODE> to exit the menu.

3.1.6 PLC Switch

SD CARD
Verify that the PLC switch is in the RUN position. SLOT
The boiler will not operate if the switch is in the PROG
position. 24

RUN/REM/PROG
The boiler will immediately stop if the switch is moved to SWITCH
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 Figure 3-5. PLC switch & SD slot
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).

3.2 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.

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C
H
1

C
H
2
FEMALE END VIEW
TYPICAL OF ALL
C SERVO CONNECTORS VIEW OF ACTUATOR W/COVER OFF
H
3

BLK TO PIN #2 24VDC RETURN

BRN TO PIN #1 RS-485 (-)
RED TO PIN #5 24VDC SUPPLY
ORG TO PIN #4 RS-485 (+)
GRN TO PIN #3 EARTH GROUND

Figure 3-6. Actuator daisy chain w/ plug connections

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.

Figure 3-7. Modbus 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.

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Actuator Node Address Table:

Actuator Address
Air Actuator 1
Fuel 1 Actuator 2
2nd Fuel 1 Actuator 3
Fuel 2 Actuator 5
2nd Fuel 2 Actuator 6
FGR Actuator 7

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.

3.2.5 Moving The Actuator

The actuator can be moved clockwise or counterclockwise by pressing either one of two red buttons located
on the actuator (Figure 3-8). 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.
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 actuator calibration screen on the HMI. These pushbuttons
should be used when calibrating the actuators.

Clockwise or counter-clockwise actuator shaft rotation is deduced from the viewing perspective shown in
Figure 3-8.

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Figure 3-8. Actuator manual pushbuttons

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 Section 4
System Configuration
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Logging In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Logging In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Fuel Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
Flame Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
CB Master Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
CB 2 Boiler Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Remote Modulation/Remote Set Point . . . . . . . . . . . . . . . . . . .4-16
Actuator Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Variable Frequency Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
Configuration Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
Email Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
SMTP Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
Text/Email Contact List . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
PanelView Plus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Change the Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Installing a PV+ Program . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
Remote Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-34

www.cleaverbrooks.com
Section 4 — System Configuration Hawk 1000

4.1 Introduction
The Hawk 1000 is equipped with a 6" 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. Firing Rate Screen

4.1.1 Logging In
Certain actions on the HMI require a password before allowing user input. The Hawk 1000 employs two levels
of security: Operator, and Service. When a password is required, the login entry window is displayed.
Pressing <User Name> or <Password> will bring up an alphanumeric keypad. Use this to enter your user
name and password. A USB keyboard may also be used.

Figure 4-2. Login Keypad

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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>).

Figure 4-3. Main Menu

Figure 4-4. Main Menu (system configuration required)

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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.

STEAM BOILERS HOT WATER BOILERS

FIRETUBE

FLEXTUBE

MODEL 4/5

Figure 4-5. Boiler Overview Screen

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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. The following
items are configurable when in system configuration:

• Boiler Media Steam or Hot Water • O2 Analyzer (when this option is selected, type
• Boiler Type - Firetube, Flextube or M4/M5 boiler of analyzer must be specified - requires
additional analog input module Slot 7)
• Safety Valve Setpoint
• O2 Trim
• NOx Level (PPM)
• Low O2 Shutdown Option
• Number of Fuels
• Hot Standby Option Selection
• Fuel 1 Fuel Type
• Combustion Air Temp Option Selection (requires
• Fuel 1 Control Type (Parallel or Single Point) additional analog input module Slot 7)
• Fuel 1 Turndown • Level Master Option selection (Steam Boiler)
• Fuel 2 Fuel Type • Return Water Temperature (hot water only)
• Fuel 2 Control Type (Parallel, Single Point, or • Outdoor Temp Reset Selection (hot water only)
Low High)
• Selectable overview screen graphic - Firetube,
• Fuel 2 Turndown Flextube, or M4/M5 boiler
• Flame Safeguard Selection • 2 Boiler Lead Lag / Master Panel Lead Lag select
• Revert to Pilot (CB120E Only) • Remote Modulation Source select (Analog Input
• Revert to Pilot Signal Select (CB120E Only) / Communications)
• Analog Input I:2.2 • Remote Setpoint source select (Analog Input /
• Remote Modulation/Setpoint Signal Selection Communications)
• Actuator Selection • Dual Set Point
• VFD Option Selection (requires additional • Enter customer name, boiler ID and serial
analog input module Slot 7) number, Alarm Input #1-3 name if enabled.
• VFD Bypass Option Selection

Note that if a configuration setting is marked with an asterisk and the setting is changed the Combustion
Curves will be erased.
2 Configuration Summary screens are available. 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.

! 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 you are in a System Configuration screen.

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Section 4 — System Configuration Hawk 1000

Note: The firing rate will be put into manual mode upon entering System Configuration.

4.4.1 Logging In
A login is required in order to access System Configuration. Pressing <System Config Required> from the
Main screen will display the following:

Figure 4-6. Enter System Configutration

Any time a gray button appears, a user I.D. and password are required for user input.
Pressing <System Config> will bring up the following screen:

Figure 4-7. Login Screen

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

Type the password (user name) followed by the Enter key.

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Figure 4-8. Keypad

When a valid user name and password have been entered, the following screen will appear:

Figure 4-9. System Configuration (user logged in)

Pressing <System Config Required> displays a final warning:

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Section 4 — System Configuration Hawk 1000

Figure 4-10. System Config Warning

Press <Next> to begin the configuration process. The first step is selection of Boiler Media and Boiler Type.

Figure 4-11. Select Boiler Media & Type

In this example, “Firetube” is selected as the boiler type. After selecting the boiler media (steam or hot water)
additional screen buttons will become available. Selecting “Steam” will bring up buttons for steam transmitter
span, safety valve setpoint, and NOx level. To change the default values, press the desired button and a keypad
will appear allowing user input.
Selecting boiler type and media will also bring up the <Next> button, allowing the user to advance to the
next configuration screen.
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.

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Hawk 1000 Section 4 — System Configuration

Figure 4-12. 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 in the top right corner of each screen.
The color of the pushbutton will also indicate if the user has proper access rights.
Pressing the button of the value that needs modifying will pop-up a numeric keypad, allowing the operator to
enter the new value. Notice that there is a range of valid entries at the top of the numeric 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.

KEYPAD INVALID ENTRY

Figure 4-13. Onscreen Keypad

Boiler Media
Select Steam or Hot Water depending on the type of system.

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Section 4 — System Configuration Hawk 1000

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).

Safety Valve Setpoint Max

Firetube 400 psi
Flextube 250 psi
M4/M5 675 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 250º F. Contact your local Cleaver-Brooks representative if you do not know the maximum temperature
rating of your boiler.

Steam Transmitter Span The span setting 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 Setpoint Steam Transmitter Span

15.0 psi 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
600.1 or greater Safety Valve Setpoint

In hot water systems the supply temperature transmitter is not scalable. The transmitters used must be rated
to accommodate the required range:
If the Max Rated Temperature O 250 Deg F the Supply Temp Transmitter is set to 50-300 Deg F.
If the Max Rated Temperature > 250 Deg F the Supply Temp Transmitter is set to 50-500 Deg F.

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NOx Level (PPM)

Enter the NOx Level for this specific job.
NOx Level can range from 5-150 PPM and is initialized with a value of 60.0 PPM.
Note: On Steam Boilers If NOx Level is less than 60.0 PPM Remote Setpoint and Dual Setpoint Options
are Not Available.
When all configurable items on this screen have valid entries, the <Next> button will appear, allowing System
Configuration to continue. The next screen is fuel configuration, where number and type of fuels, turndown,
and combustion control method are selected.

4.4.2 Fuel Configuration

Figure 4-14. Fuel configuration

Number of Fuels
Enter the Number of Fuels for this application.
Acceptable values are either 1 or 2. High/Low control method MUST be fuel 2.
If the system has only one fuel and that fuel is Oil, the number of fuels must be selected as 2 and Oil must
be Fuel 2. Fuel 1 Actuator does not require commissioning.

Fuel 1/Fuel 2 Type

Select the Fuel type for each fuel for this specific job
When pressing the Fuel Type push button a selector is
displayed

The up/down arrows can be used to select the correct fuel.

Press the enter key to accept the selection.

Fuel 1/Fuel 2 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.

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Section 4 — System Configuration Hawk 1000

Fuel 1/Fuel 2 Control Method

Select the type of control method for each fuel for this specific job.
Acceptable values for fuel 1 are Parallel Positioning or Single Point positioning.
Acceptable values for fuel 2 are Parallel Positioning, Single Point positioning or Low/High.
Note - Single Point positioning cannot be selected in conjunction with parallel positioning.

When fuel configuration is complete, press <Next> to go to Flame Safeguard configuration.

4.4.3 Flame Safeguard

Figure 4-15. FSG screen

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

Revert to Pilot
The Revert to Pilot selection is made by pressing the <Revert to Pilot> push button until “Yes” is displayed
on the pushbutton.
If Revert to Pilot is selected there are two ways to initiate the Revert to Pilot sequence - either by Process
Variable (Steam Pressure/Supply Temperature) or by Digital Input.
If Process Variable is selected the setpoint for Revert to Pilot must be entered from the Setpoint Screen - see
Section 5 E - Setpoints for more details.
If Digital Input is selected, when discrete input I:5.7 ALFCO is turned off, Revert to Pilot will be initiated (as
long as the boiler is not currently in hot standby or warmup mode).

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

4.4.4 Analog Inputs

Figure 4-16. Analog Inputs (steam)

Analog Input I:2.2
For Steam systems it is mandatory that Analog Input I:2.2 is Water Temperature
For Hot Water systems Analog Input I:2.2 can be selected as None, Outdoor Temperature, or Return
Temperature.

Analog Input I:2.3

For Steam systems Analog Input I:2.3 can be selected as None, Water Level, Remote Modulation, or Remote
Set Point.
If the boiler is configured as a CB Master Lead/Lag or Two Boiler Lead Lag then this input will be used for the
hardwired analog input from the Master Panel or Two Boiler Lead Lag Master.
If Water Level is selected it is mandatory that the CB Level Master is the sensor used to measure the water
level.
Remote Set Point is not available on Low Emission boilers <60ppm.
For Hot Water systems Analog Input I:2.3 can be selected as None, Remote Modulation, or Remote Setpoint

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Section 4 — System Configuration Hawk 1000

If Analog Input I:2.3 is used for Remote Modulation or Remote Set Point then neither Remote Modulation by
communications or Remote Setpoint by communications are available.

4.4.5 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.
The figure below shows the different system configuration options available.

MASTER SELECTED [WATER LEVEL, REM MOD,

REM SP DISALLOWED]

[DUAL SETPOINT DISALLOWED] [HOT STANDBY SELECTED]

Figure 4-17. CB Master Lead Lag

Note that with CB Master Lead Lag enabled, certain boiler configuration selections will be automatically
determined and their buttons deactivated (signified by a gray button).

4.4.6 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 above).
If Master is selected, the 2 Boiler Lead Lag Setup and Control screens will now be available from the Main
Menu.
CB 2 Boiler Lead Lag is available Hardwired or by Communications beginning with PLC program revision
98500509_001_011 (or 98500509_001_012 metric).
Note that with CB 2 Boiler Lead Lag enabled, certain boiler configuration selections will be automatically
determined and their buttons deactivated (signified by a gray button).

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Hawk 1000 Section 4 — System Configuration

MASTER SELECTED [REM MOD/ REM SP DISALLOWED]

[DUAL SETPOINT DISALLOWED] HOT STANDBY SELECTED

Figure 4-18. 2 Boiler Lead Lag

Two Boiler Lead Lag allows for Water Level selection:

• on the Master boiler
• on the Slave boiler if Lead Lag by Communications is enabled

2 BLR LL WATER LEVEL

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Section 4 — System Configuration Hawk 1000

4.4.7 Remote Modulation/Remote Set Point

Signals for Remote Modulation or Remote Setpoint can be provided by either an analog input signal or written
directly into the PLC by communications (Ethernet).

Remote Modulation by Analog Input

This configures the Boiler Controller to receive a remote
4-20mA signal on input I:2.3 to control the firing 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
Figure 4-19. Remote Modulation signal select
Remote Modulation by isolated contact input signal (120
VAC) on digital input I:5.14. 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 revert 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 Figure 4-20. Remote Mod/Setpoint by Communications
This configures the Boiler Controller to receive a remote
4-20mA signal on input I:2.3 to vary the set point of the boiler.
N o t e : R e 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

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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 I:5.14. 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.
If the PLC detects a bad analog signal, an alarm “Remote
Setpoint Signal Failure” is activated and the Set point revert to Figure 4-21. Remote SP Analog Select
the LOCAL setting on the HMI.

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 back to the LOCAL setting on the HMI

Figure 4-22. Remote SP by Comms

! 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.

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 I:5.14.
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. Figure 4-23. Dual Set Point

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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 deter-
mine 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.

4.4.8 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
The Fuel 2 Actuator 2 should be selected as “Yes” if it is present on this system. This actuator is only available
for parallel positioning control.

Figure 4-24. Actuator selection

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4.4.9 Variable Frequency Drive

VFD Type
Select the appropriate VFD Type for this specific job.
The available options are None, PowerFlex, and Other Mfg.
Selecting <PowerFlex> assumes you are using either the PowerFlex 400, PowerFlex 70 Enhanced, or
PowerFlex 700 Vector drive.
All drives types use 4-20mA command and feedback.

VFD Bypass
VFD Bypass should be selected “Yes” if VFD Bypass is on this specific job.
An Air/Fuel curve must be configured for each fuel while in bypass mode.
VFD bypass allows the boiler system the ability to keep the combustion blower motor running even if the
Variable Frequency Drive is taken out of the loop for any reason.

Figure 4-25. VFD screen

Variable Frequency Drive for Combustion Air Fan Motor
Variable frequency drives (VFDs) offer many benefits to reduce energy costs and extend the life of mechanical
equipment.
The optional Variable Frequency Drive (VFD; see Figure 2-7) controls the speed of the combustion air fan
motor for the purposes of improving boiler efficiency and reducing electrical energy consumption.

4.4.10 Options

Oxygen Analyzer
The Oxygen (O2) Analyzer (See Figure 2-8) 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

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Section 4 — System Configuration Hawk 1000

Shutdown and in calculating boiler efficiency. O2 concentration is displayed on the Boiler Overview and Firing
Rate screens.

Figure 4-26. O2 Analyzer

O2 Trim
02 trim control is an integral part of the HAWK 1000 system. This feature affords additional control over fuel-to-
air ratios in the event of adverse atmospheric conditions or fluctuating fuel heating values.
The HMI has an 02 trim screen that displays O2 Actual concentration and O2 Setpoints. The Screen allows for
viewing and calibrating the Cleaver Brooks O2 Sensor (CB) and also allows for adjustment of PID tuning. The
Flue Gas O2 Control Screen can be accessed from the HMI Main screen.

Figure 4-27. Flue Gas O2 Control Screen

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.

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Figure 4-28. Low O2 Shutdown

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).
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.
If two boiler Lead Lag or CB Master Panel Lead Lag is selected, Hot Standby is automatically enabled and
cannot be changed by the user.
If two boiler Lead Lag or CB Master Panel Lead Lag is selected and the control is operating in Remote Mode,
Force Hot Standby is automatically disabled and cannot be enabled by the user.
See Section 5 - Commissioning for more on Hot Standby.

Overview - Hot Standby Force Hot Standby

Figure 4-29. Hot Standby

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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 Anal o g I n put 2 .2for this feature. When the outdoor temperature is selected for Ana l o g
I n p u t 2.2 outdoor temperature is displayed on the boiler overview screen.

Figure 4-30. Outdoor Reset

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.
Outdoor Temp Reset is not available if Remote Setpoint by Analog or Remote Setpoint by Communications is
selected.

Figure 4-31. Outdoor Reset not available

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. Analog input
module required (Slot 7).
Surface Thermocouple
Used on Hawk retrofits where a temperature probe is not available for shell water temperature input.
The surface thermocouple is automatically scaled to 32-1292 Deg F (0-700 Deg C).

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Figure 4-32. Combustion Air Temp, Surface

Thermocouple select

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

Figure 4-33. 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.

Auxiliary Alarm 1-3

If the system has auxiliary alarms the text that is displayed when the 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 1 Input 13

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Section 4 — System Configuration Hawk 1000

Auxiliary alarm 2 must be wired to Slot 1 Input 14

Auxiliary alarm 3 must be wired to Slot 1 Input 15
For example: If Auxiliary Alarm 1 is entered as Low Water Flow and Discrete Input I:1.13 is “On” the alarm
displayed on the HMI for Auxiliary Alarm 1 will read “Aux 1 - Low Water Flow”.

Figure 4-34. Aux inputs

4.4.11 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.

Page 1 Page 2

Figure 4-35. Configuration summary

To complete system configuration, press the <Confirm Options> pushbutton on the Options Summary Screen.
The Configuration selections may be changed after the HAWK 1000 is installed. However, for many of the
options, additional hardware is required to make the function work. Please refer to the parts section for the
required hardware.
After confirming the current configuration, press <Main> to return to the Main screen.

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Figure 4-36. Configuration Confirmed

4.5 Email Setup

Email or text messages can be send directly from the PanelView Plus, provided SMTP Server Configuration
has been completed.
The PV+ 7 must be at firmware revision 9.0 or greater.
4.5.1 SMTP Configuration
SMTP (Simple Mail Transfer Protocol) is a standard protocol for the exchange of electronic mail over the
Internet. It will be the user’s responsibility to determine the SMTP server information for email configuration;
an example configuration is shown below. A help screen is available (press <SMTP Help>). User’s IT
personnel should be consulted if necessary.

Figure 4-37. SMTP Configuration (example)

4.5.2 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.

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Figure 4-38. Email List

4.6 PanelView Plus Setup

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

4.6.1 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 4-39. Date Settings

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.

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Figure 4-40.
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 4-41.

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Section 4 — System Configuration Hawk 1000

4.6.2 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-UM007D-EN-P - December 2015

Copy Application File

In most cases, the application will arrive in a compressed (zip) file. Extract the file to a known location and
copy the folders to the root directory of a USB flash drive or an SD card.

It is strongly advised that you have only one .mer file in this folder structure to reduce potential loading errors.
Install your memory device into the approprate location on the rear of the terminal.
Then copy the FactoryTalk View ME Station application .mer files from the storage location to the terminal.

1. Press Terminal Settings>File Management>copy Files>Copy Applications

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2. Press Source to select the location of the file you want to copy:

• External Storage 1 - SD card loaded in the card slot of the terminal

• External Storage 2 - USB flash drive connected to a USB host port

3. Select a file from the storage location.

4. Press Destination on the same dialog box.
5. Press Destination to select the location to copy the file. The destination must be different than the source
location, and should be Internal Storage.

6. Press Copy to copy the selected file to the destination. If the file exists, you are asked if you want to
overwrite the file.
7. Select Yes or No.
8. Return to the FactoryTalk View Machine Edition Configuration Dialog box by pressing Close as required.

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Section 4 — System Configuration Hawk 1000

Load Application
It is recommended that prior to loading an application that the terminal Ethernet is connected to only the PLC
Ethernet. Do not connect to the plant network until the configuration is complete.
To run a FactoryTalk View ME .mer application on the terminal, you must first load the application. You can
load the application from internal storage or nonvolatile memory in the terminal, an SD card, or a USB flash
drive. However, it is recommended that you always copy and run the application from the internal storage.
Follow these steps to load and run an application.
1. Press Load Application from the FactoryTalk View ME Station dialog box.

2. Press Source to select the location of the file you want to load:

• Internal Storage - nonvolatile memory of the terminal (preferred).

• External Storage 1 - SD card loaded in the card slot of the terminal.
• External Storage 2 - USB flash drive connected to a USB host port.

3. Select the .mer file from the list by using the up and down cursor keys.
Note: There should only be one application loaded on the terminal to eliminate the possibility of loading the
incorrect application. Refer to Delete Application section to remove unused applications.
4. Press Load to load the selected application.

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You are asked if you want to replace the terminal's communication configuration with the configuration in the
application.

5. Select Yes or No.

Select Yes to use the communication settings in the application. Use this option if this is a new installation.
The PLC processor communications path will use IP address 192.168.1.101.
Select No to use the communication settings of the terminal. Use this option if you are running the application
on a previously configured system in which the PLC processor communications path was changed.

6. To run the application that you loaded, press Run Application on the FactoryTalk View ME Station dialog
box.

TIP: Applications generate log files (trends, alarm history, etc). To delete log files before running an application,
select Delete Log Files Before Running on the Configuration Mode dialog box. Deleting log files reclaims
terminal memory. It is recommended to select No.

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Section 4 — System Configuration Hawk 1000

Configure Ethernet Settings

The terminal has a built-in Ethernet driver. To view or enter an IP address for your terminal, follow these steps.
1. Press Terminal Settings, then choose Networks and Communications>Network Connections>Network
Adapters.

2. To view or modify the IP address, press IP Address.

Standard C-B terminal addressing

Hawk 1000, Hawk 4000,
Hawk 5000, Hawk 6000
Hawk 4000 v2, ADAC
Master Panel 192.168.1.120 Plant Master 192.168.1.180
Boiler #1 192.168.1.121 Boiler #1 192.168.1.181
Boiler #2 192.168.1.122 Boiler #2 192.168.1.182
Boiler #3 192.168.1.123 Boiler #3 192.168.1.183
Boiler #4 192.168.1.124 Boiler #4 192.168.1.184
Boiler #5 192.168.1.125 Boiler #5 192.168.1.185
Boiler #6 192.168.1.126 Boiler #6 192.168.1.186
Boiler #7 192.168.1.127 Boiler #7 192.168.1.187
Boiler #8 192.168.1.128 Boiler #8 192.168.1.188
ADAC 192.168.1.152

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3. To enable or disable DHCP assignment of addresses, press Use DHCP. Select No.
If DHCP is enabled or set to Yes, IP addresses are automatically assigned to newly attached devices on the network.
Cleaver-Brooks does not use this selection.
If DHCP is disabled or set to No, you can manually enter the IP address. Press IP Address, Subnet Mask, and
Gateway to enter IP formatted addresses. For Cleaver-Brooks systems, you must select this option.
4. Press OK when done.
If prompted, reset the device from the FactoryTalk View ME Station dialog box.
5. Press Close.

Change the communications path

The application is generally sent with the communications path set to the default PLC IP address. Should this
need changing to satisfy customer's network requirements:
1. Press Terminal Settings>Networks and Communications>RSLinx Enterprise Communications.

2. Select the controller in the tree.

Note: The 1769-L32E and 1769-L35E processors will be seen differently than the 1769-L24ER, 1769-L30ER, and
1769-L33ER. Select the path accordingly.
• For the 1769-L32E and 1769-L35E processors, if the PLC program number is not highlighted, use the arrow keys to
do so.
• For the 1769-L24ER, 1769-L30ER, and 1769-L33ER processors, if the controller is not highlighted, use the arrow
keys to do so.

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Section 4 — System Configuration Hawk 1000

4.6.3 Viewing the PV+ Firmware

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

Figure 4-42. View Firmware

4.7 Remote Monitoring

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

Figure 4-43. Remote monitoring

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 Section 5
Commissioning
Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Setting Combustion - Parallel Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Store Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Store Lightoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Curve Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
No VFD or O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Setting Combustion - Low/High/Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Remote Setpoint/Remote Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Alarms and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
High Stack Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Low O2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Low Steam Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
FR Limit, SP Limiting, Remote SP Scaling, Extended Pre-Purge, External Device Timer 5-11
Mod. Rate Limiter, Max. O2 Correct, Remote Shutdown by Comms. . . . . . . . . . . . . 5-12
Stack Low Temp. Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Operating Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Outdoor Temperature Reset (Hot Water only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Hot Standby. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Revert to Pilot (CB 120E only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
O2 Trim . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Drive Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Ethernet Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Two Boiler Lead Lag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Lead Lag Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Lead Lag Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Thermal Shock Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

www.cleaverbrooks.com
Section 5 — Commissioning Hawk 1000

5.1 Commissioning the Actuators

When system configuration is complete, the <Calibrate Actuators> button will be available on the Main
screen and will indicate “Required”.

Figure 5-1. Actuator calibration required

Press <Calibrate Actuators> for the Actuator Commissioning screen, where air, fuel, and FGR actuators can
be individually selected for commissioning. 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 begun. Press <Enable Air Actuator Commissioning> on the warning screen 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).

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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 means the closed position will be greater than the open position.
CW rotation means the open position will 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.
<Test Close> and <Test Open> will move the actuator to the stored close/open position with a single press
of the button.
When valid data have been entered, the <Save Air Actuator Configuration> button will appear. Press to save
data, then press <Next Actuator> and repeat the above steps.

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Section 5 — Commissioning Hawk 1000

Invalid Data Save Data

Figure 5-5. Verify actuator calibration

5.2 Setting Combustion - Parallel Positioning

When actuators for the currently selected fuel have been calibrated, the <Set Combustion> button will be
available on the Main screen. To begin the procedure, press <Set Combustion> and observe the warning that
follows.

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.

2nd Warning

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5.2.1 Store Purge

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

Figure 5-7. Purge/Lightoff help

For a valid Purge position the air actuator must be greater than 80% open. To position the actuators in setting
combustion, first press the button for the desired actuator on the Combustion Setup screen.

Press to
adjust
actuator

Figure 5-8. Combustion Setup

Next, use the <Dec> and <Inc> buttons to move the air actuator to the desired position.

Figure 5-9. Adjust actuator

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Section 5 — Commissioning Hawk 1000

When purge position is set, press <Store Purge>. When prompted with “Store Current Values?”, press <Store
Purge> again to confirm or <Cancel> to re-adjust.

Note: If a VFD is present, the VFD purge value is automatically

set at 100%.

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 5-10. Store Purge

Figure 5-11. Position actuators in lightoff Figure 5-12. Store Lightoff

5.2.3 Curve Setup

A help screen is available to guide the user through the steps of setting the combustion curve:

Figure 5-12. Combustion setup help

To set the combustion curve, the burner must be on. If all conditions to start the boiler have been met, the
<Burner Start> pushbutton will appear on the Combustion Setup screen. Press <Burner Start>; the purge

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sequence will run and the actuators will return to the lightoff position. Press <Lightoff>. The Flame Safeguard
will sequence through pilot trial and main flame and the burner will ignite. The actuators can now be
positioned for the first point.
• 8 points minimum must be stored for a valid curve (16 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 (8 valid points are stored) the <Firing Rate> button will appear,
replacing the <Main> button.
• Pressing <Pt Adv Enable> will allow stepping through the combustion curve using <Next> and <Prev>.
With Points Advance disabled, the actuators will not move when <Next> or <Prev> is pushed.

Figure 5-13. Combustion curve complete

5.3 Setting Combustion - Single Point Positioning

5.3.1 VFD or O2 Trim
If VFD or O2 Trim is selected, combustion setup is identical to parallel positioning, with the exception that
only the air actuator will be active. 8 points minimum are required for the combustion curve, with 16 points
maximum.

5.3.2 No VFD; No 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.

5.4 Setting Combustion - Low/High/Low

Low/High/Low combustion is only available with Cleaver-Brooks Model 4/Model 5 boilers.
Low/High/Low is only available for Oil (as Fuel 2). The combustion curve consists of 2 points; only the air
actuator is active. Point 1 will be low fire; Point 2 will be high fire.
A View/Adjust Setpoints screen is provided.

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Section 5 — Commissioning Hawk 1000

Figure 5-14. View/Adjust Setpoints

When using Low/High/Low combustion the boiler firing rate will be either 0% or 100%. The oil valves open
and close based on the air actuator feedback percent. The high fire and low fire setpoints are limited by the
Boiler On and Boiler Off points.
When steam pressure is greater than the low fire point, the firing rate will go to 0%.
When steam pressure is less than the high fire point, the firing rate will go to 100%.

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.

MANUAL AUTO REMOTE

Figure 5-15. Firing Rate

In Automatic mode, control output is based on demand; the actuators will be positioned according to the
currently active combustion curve.
While in Automatic the boiler can be forced to low fire by isolated 120VAC contact signal on digital input
I:5.4. The boiler will remain at low fire until this signal is removed.
The Firing Rate screen also allows selection of Remote Setpoint or Remote Modulation for interfacing with a
Building Management System or other control system.

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Figure 5-16. Remote Signal Fail

In the event of a bad remote signal, an alarm message will appear on the screen and the control will revert to
Local/Auto mode.
The <Adjust Gains> button accesses the system PID tuning. Default values are: P=5, I=5, D=0.

Figure 5-17. Adjust Gains

<Adjust Setpoint> allows adjustment of Setpoint 1 and Setpoint 2 (if dual setpoint is configured).

Figure 5-18. Adjust Setpoint

<View Actuator> shows setpoint and feedback signals for all configured actuators.

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Section 5 — Commissioning Hawk 1000

Figure 5-19. View Actuators

The <Manipulate Actuators> button allows the actuators to travel through 0-100% of firing rate to verify all
actuators are positioning correctly at the current firing rate. To use this feature, the Burner Switch must be
OFF and firing rate must be in MANUAL mode. While manipulating the actuators, output and firing rate are
not rate limited.

5.5.1 Remote Setpoint/Remote Modulation

If Remote Setpoint or Remote Modulation is configured, the appropriate display and controls will appear on
the Firing Rate screen.

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

Remote modulation by digital input. Digital input is off; firing Remote setpoint by digital input. Digital input is off; setpoint
rate reverts to local control reverts to local control

Remote mod. by HMI Remote setpoint by Comms.

Remote mod. by Comms Remote setpoint by HMI.

Figure 5-20. Remote Setpoint/Remote Modulation

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5.6 Alarms and Limits

Alarms with configurable parameters and firing rate/setpoint limits can be edited from this screen.
Configurable items include the following:

5.6.1 High Stack Temperature

Select Alarm and Shutdown points.

5.6.2 Low O2
Select Low O2 Alarm, Shutdown, and Alarm Delay points. Low O2
Alarm only available with selection of an O2 analyzer. Shutdown only
available if selected in the System Configuration menu.

5.6.3 Low Steam Pressure

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

Figure 5-21. Alarms and Limits - Low O2

Figure 5-22. Alarms and Limits - Low

Steam Pressure

5.6.4 Firing Rate Limit, Setpoint Limiting, Remote SP Scaling, Extended Pre-Purge, External Device Timer
The Firing Rate Limit value can be used to limit the maximum control output from the HAWK 1000. 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 1000 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. Figure 5-23. Alarms and Limits - Firing
Rate Limit
Extended Pre-Purge Time extends pre-purge by up to 180 seconds.
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.

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Section 5 — Commissioning Hawk 1000

5.6.5 Mod. Rate Limiter, Max. O2 Correct, Remote Shutdown by Comms.

Modulation rate limiting increases/decreases the rate of change of

firing rate output. The value entered is the number of seconds the
control output will take to go between 0-100%
Maximum O2 Trim Correction is the value plus or minus that the VFD or
Air Actuator can correct (+/- 10% maximum).
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).
Figure 5-24. Alarms and Limits - Mod.
Two help screens are available for Remote Shutdown. Rate Limiter

REMOTE SD HEARTBEAT HELP

REMOTE SHUTDOWN HELP

Figure 5-25. Remote Shutdown Help

5.6.6 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 (4 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 Figure 5-26. Alarms and Limits -
and go to the firing rate commanded position. Stack Low Temp Hold
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

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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.

5.7 Setpoints
5.7.1 Operating Setpoint

Setpoint 1 Setpoint 2

Figure 5-27. Operating Setpoint

Steam Pressure (Water Temperature) setpoint and on/off differential are set here. If dual setpoint is selected,
the Operating Setpoint 2 can be entered from the HMI but the ON/OFF points are calculated using the same
dP/dT as Setpoint 1.
Set Point = steam pressure (water temperature) operating setpoint
On Point = Set Point + (On dP% x Set Point)/100. Valid entries for On dP are from -50% to Off dP%.
Off Point = Set Point + (Off dP% x Set Point)/100. Valid entries for Off dP are from On dP% to the calculated
value where Off Point is not greater than the Safety Valve setpoint.

5.7.2 Outdoor Temperature Reset (Hot Water only)

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

Figure 5-28. Outdoor Reset screen

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Section 5 — Commissioning Hawk 1000

OUTDOOR RESET CURVE

Set point is linear in relation to the outdoor temperature.

Range for outdoor temperature transmitter is 4 ma = -50 deg F, 20 ma = 900 deg F.
In this example:
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 5-29. Outdoor reset curve

5.7.3 Hot Standby

Hot Standby when active will cycle the boiler on if the shell water temperature (steam boilers) or supply water
temperature (hot water boilers) drops 5 degrees F below the “Hot Standby Temp”. The boiler will remain at
low fire until the shell (supply) water temperature reaches the “Hot Standby Temp” at which time the boiler
will turn off. I:5.7 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).

5.7.4 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 O:6.4 is energized, and the Revert to Pilot signal
is sent to the flame safeguard. The RTP sequence is managed by the FSG: pilot is energized, and upon proof
of pilot the main gas valve de-energizes and the boiler remains on pilot. When demand returns or digital input
I:5.7 is ON the main gas valve is energized.
When RTP is on a “Rev to Pilot” indicator will appear on the 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”.

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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 5-30. Revert to Pilot

Initiated by digital input
If ‘Initiate by digital input’ is selected, the above screen will not be shown; Revert to Pilot will be initiated when
digital input I:5.7 ALFCO is OFF.

5.8 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 5-31. O2 Trim

O2 Trim is accomplished by means of the air actuator, or by the VFD if present (if VFD is in Bypass, the air
actuator is used). A manual operating mode is provided for diagnostic or testing purposes.
The CB O2 analyzer requires calibration on power up, or if one week has elapsed since the last calibration. If
using the Yokogawa analyzer, the PLC will expect a “Sensor OK” input from the analyzer at input I:5.2.
Once the O2 sensor is calibrated or “Sensor OK” input is on, the O2 setpoint is captured when setting
combustion curves.

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Section 5 — Commissioning Hawk 1000

PID control of O2 Trim is provided. Values can be adjusted by pressing <Adjust Gains>. Defaults are P=3,
I=5, and D=0.

O2 Calibration Calibration Help Screen

Figure 5-32. O2 Calibration

5.9 Drive Data

If a VFD is present, <Drive Data> will display a read-only screen showing drive output and feedback, Low/
High/Lightoff settings, and current running frequency.

5.10 Ethernet Configuration

In order to configure the Ethernet port, the PLC switch must be in REM and the RUN LED must be GREEN.
Multiple boilers on the same Ethernet network require unique IP addresses. To change a boiler’s configuration,
press the desired field in the “Set New Ethernet Configuration” area. If user is logged in at the proper level, a
numeric keypad will appear. Enter the new data and press the enter key (or use the PV+ keypad). When
finished, go to <Set Enet Config> and when prompted with “Set PLC Ethernet Port Configuration?” press
<Yes>.

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Figure 5-33. 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 Appendix, “Procedure to Load and Setup a PV+”.

5.11 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
I:7.3.
Beginning with PLC program revision 98500509_001_011 (or 98500509_001_012 metric), Two Boiler
Lead Lag can be accomplished with a hardwired solution or via Ethernet communications.

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Section 5 — Commissioning Hawk 1000

Figure 5-34. Typical Two Boiler Lead/Lag system (hard wired)

Figure 5-35. Two Boiler Lead/Lag by Communications

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.

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5.11.1 Lead Lag Setup

Select Modulation - Select Lead Lag (steam boilers only) or
Unison modulation.
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 Figure 5-36. 2 Boiler Lead Lag Setup
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.
If two boiler lead lag master is enabled and is via communications an additional screen will be available to
set the IP address of the slave boiler. The IP address of the slave boiler must be entered from the 2 Boiler
Slave IP Setup Screen.

SLAVE IP NOT SET SLAVE IP SET

Figure 5-37. Slave IP Setup

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Section 5 — Commissioning Hawk 1000

5.11.2 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 boiler’s firing rate screen.
Lead Lag Modulation - The lag boiler starts when the lead
boiler’s firing rate signal reaches the Start Point (and the
Start Delay has expired). The lag boiler starts modulating
after the lead boiler reaches the configured Modulation
Start point. The lag boiler is commanded to stop when the
lead boiler’s firing rate signal reaches the Stop Point (and
the Stop Delay has expired). Figure 5-38. Lead Lag Control
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. Hot Water systems must use unison modulation.

5.12 Thermal Shock Routine

To protect against thermal shock, the Hawk 1000 incorporates a routine to prevent the boiler water
temperature from rising too rapidly on a cold startup.
Steam boilers
Thermal shock protection is activated when the boiler water temperature is below 60% of the steam saturation
temperature at set point. If the boiler is in thermal shock protection and released for modulation, and water
temperature is above the hot standby off temperature*, a timer is activated. The boiler firing rate is
incremented once every 126 seconds. Thermal shock is deactivated when boiler water temperature reaches
90% of the saturated temperature at set point.
It will not be re-activated unless temperature drops below 60% of the steam saturation temperature with the
fuel valve terminal de-energized, or if the fuel valve has been de-energized for more than 8 hours.
For Hot Water Boilers
Thermal shock protection is activated when actual water temperature is below minimum temperature (150F
for Firetube or 120F for FLX). If the boiler is in thermal shock protection and released for modulation, and
water temperature is above the hot standby off temperature*, a timer is activated. The boiler firing rate is
incremented once every 60 seconds. Thermal shock is deactivated when hot water temperature reaches 90%
of set point.
It will not be re-activated until temperature drops below minimum temperature with the fuel valve terminal
de-energized, or if the fuel valve has been de-energized for more than 8 hours.
*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.

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 Section 6
Diagnostics and Troubleshooting
System Monitoring and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Boiler Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Burner Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
PLC Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Diagnostic Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
PLC I/O Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Combustion Curve Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
PLC Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

www.cleaverbrooks.com
Section 6 — Diagnostics and Troubleshooting Hawk 1000

6.1 System Monitoring and Diagnostics

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

Figure 6-1. Overview screen

6.1.2 Burner Control

The Burner Control screen gives details on the installed Flame Safeguard (CB780 or CB120).

Burner Control - CB780 Burner Control - CB120

Figure 6-2. Burner Control screens

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”

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is indicated. When the system Pressure/Temperature drops below the “On Point”, load demand will again be
displayed.
Limits -This is an indication of the status of the running interlocks on the boiler.
External Interlock - Feedback input from external interlock. When there is a load demand, and the burner
switch and limits are closed, the HAWK 1000 has isolated contacts (2.5A @ 125VAC) for output to an
external interlock device (e.g. fresh air damper, circulating pump). The boiler will start once the external
interlock is proven.
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

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.

Figure 6-3. System Information

6.1.4 PLC Info

Figure 6-4. PLC Info

This screen duplicates the L24 Status LEDs and in addition shows the current PLC firmware revision, serial
number, and PLC switch position.

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Section 6 — Diagnostics and Troubleshooting Hawk 1000

6.1.5 Diagnostic Screens

Press <Diagnostic> on the Main screen for the diagnostic
screen menu. Select an item from the menu to show a
detailed view of the corresponding program logic. Items in
green are TRUE and those in white are FALSE.

Figure 6-5. Diagnostics screen

6.1.6 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 6-6. PLC I/O Status

6.1.7 Combustion Curve Data

This screen shows the combustion curve for the selected
fuel.

Figure 6-7. Combustion Curve

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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 6-8. 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.

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Section 6 — Diagnostics and Troubleshooting Hawk 1000

6.2.1 Troubleshooting

Fault Text System Failure Condition Recommended Troubleshooting

Alarm from flame safeguard Power present to PLC
Burner Control Alarm See flame safeguard manual.
alarm terminal. input I:5/12
1. Check for proper baud rate setting
on the flame safeguard. Must be
9600 for CB780E and 4800 for
CB120E.
Modbus 2. Check dip switches settings on PLC
Burner Control Modbus Comm Communication message
Communication to the SM2 Modbus module.
Error error
flame safeguard failed. 3. Check cable and connectors.
4. CB780E uses Modbus channel 1
while CB120E uses Modbus
channel 3 on
5. the SM2 Module.
Power present at PLC Correct per boiler operating or level control
Water Level Low Low water level shutdown
input I:5/13 manual.
Power present at PLC
Water Level High (Steam Boiler) High water level warning Check water level
input I:1/9
Auxiliary Low water Cut Off PLC Input I:1/1 is Correct per boiler operating or level control
Aux Low Water Cutoff
Alarm energized manual.
With load demand present
Refer to the wiring diagram and check for open
and burner switch
Boiler operating limits are limits. If expanded diagnostic item is
Boiler Operating Limits Open “On”(I:5/15), operating
open. purchased, there will be an indication for each
limits (I:5/5) are not
specific limit.
complete for 15 seconds.
Boiler High Operating limits PLC Input I:1/0 is Refer to the wiring diagram and check for open
Boiler High Limit Alarm
is open energized limits.
1. Check external limits.
No power to the PLC input 2. If external limits are not used, put a
External Interlock Alarm External device open.
I:5/6 3. wire jumper between 120 VAC and
I:5/6.
1. Check alarm settings.
Steam Pressure Low (Steam Steam pressure below low
2. Set low pressure alarm set point to 0 to
Boiler) pressure alarm set point.
disable alarm.
1. Check analog input wiring.
Analog input I:2/0 is
2. Check jumper between Vin0+ and I
Steam Pressure Sensor Failure outside of range.
Pressure Sensor failure in0+
(Steam Boiler) Range> 3.3 ma
3. View analog input raw value on HMI
Range<20.5ma
PLC I/O screen.
1. Check analog input wiring.
Analog input I:2/0 is
2. Check jumper between Vin0+ and I
Water Temperature Sensor outside of range.
Temp Sensor failure in0+
Failure (Hot Water Boiler) Range> 3.3 ma
3. View analog input raw value on HMI PLC
Range<20.5ma
I/O screen.
Low combustion air PLC Input I:1/8 is Check combustion air fan. Verify VFD
Combustion Air Pressure Low
pressure energized Parameters
High combustion air PLC Input I:1/11 is Check combustion air fan. Verify VFD
Combustion Air Pressure High
pressure energized Parameters
Water Flow Low (Hot Water Power present at PLC
Water Flow Low warning Check water flow or flow switch
Boiler) input I:1/9
1. Check alarm settings.
Water Temp Low (Hot Water Water Temp below low
2. Set low Temp alarm set point to 0 to disable
Boiler) Temp alarm set point.
alarm.
PLC logic is not calling for
non-recycle limit relay
Non-Recycle Limit Relay Failed output (O:6/2), but pilot Check wiring.
(I:5/8) or main fuel (I:5/9)
inputs are “On”

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Hawk 1000 Section 6 — Diagnostics and Troubleshooting

Fault Text System Failure Condition Recommended Troubleshooting

PLC logic is not calling for
recycle limit relay output
Recycle Limit Relay Failed (O:6/0), but pilot (I:5/8) or Check wiring.
main fuel (I:5/9) inputs
are “On”
1. Check analog input wiring.
With water Level option
2. Measure analog input.
selected Analog input I:2/
Water Level Signal Failure 3. Check jumper between Vin0+ and I
Water Level Sensor failure 3 is outside of range.
(Steam Boiler) in0+
Range> 3.3 ma
4. View analog input Raw value on the HMI
Range<20.5ma
PLC I/O status screen.
With remote mod by
analog, CB Master LLag, 1. Check analog input wiring.
or 2 Boiler LLag Slave 2. Measure analog input.
option selected, Analog 3. Check jumper between Vin0+ and I
input I:2/3 is outside of in0+
range. 4. View analog input Raw value on the HMI
Remote Modulation Signal Range> 3.3 ma PLC I/O status screen.
Remote Mod Signal Failed
Failure Range<20.5ma 5. Verify System Configuration settings on
HMI

With 2 Boiler LLag Slave 1. Verify that the 2 Boiler Lead Lag Master
by comms selected main Header Transmitter analog input I:7.3 is
Header loss is via OK.
communication
1. Check analog input wiring.
With remote setpoint 2. Measure analog input.
option selected Analog 3. Check jumper between Vin0+ and I
Remote Setpoint Signal input I:2/3 is outside of in0+
Remote Set Point Signal Failure
Failed range. 4. View analog input Raw value on the
Range> 3.3 ma HMI PLC I/O status screen.
Range<20.5ma 5. Verify System Configuration settings on
HMI.
1. Check combustion.
2. From system config screen check if
correct O2 analyzer is selected.
O2 level below alarm set
Low Oxygen in Flue Gas Low Oxygen level in flue gas 3. Check analyzer wiring.
point or below 0.5%.
4. Verify O2 Calibration voltage if CB
analyzer
5. is selected.
1. Check combustion.
2. From system config screen check if
correct O2 analyzer is selected.
Low Oxygen in Flue Gas Low Low Oxygen level in O2 level below Shutdown
3. Check analyzer wiring.
Shutdown flue gas set point.
4. Verify O2 Calibration voltage if CB
analyzer
5. is selected.
O2 signal (input I:7/2)
O2 analyzer calibration
must be between 4 and 1. Check wiring.
O2 Sensor Calibration Failed failed (Only applicable to
6.5 VDC during Repeat calibration.
CB O2 analyzer)
calibration
PLC Input I:1/2 is
Fuel 1 Pressure Low Low fuel1 gas pressure energized (Fuel 1 is Check gas pressure regulator.
Selected)
PLC Input I:1/3 is
Fuel 1 Pressure High High fuel1 gas pressure energized (Fuel 1 is Check gas pressure regulator.
Selected)

Part No. 750-366 6-7

Section 6 — Diagnostics and Troubleshooting Hawk 1000

Fault Text System Failure Condition Recommended Troubleshooting

With burner switch “On”
PLC Input I:5/15 Check wiring. Depending on the Number of
energized, PLC inputs I:5/ Fuels selected either, None of the Fuel
No Fuel Selected Fuel is not selected
10 and I:5/11 are de- Selected PLC inputs are on, or more than one
energized or are both Fuel Selected PLC inputs are on.
energized.
PLC Input I:1/2 is
Fuel 2 Temperature Low Low heavy oil temperature energized (Fuel 2 is Check oil temperature.
Selected)
PLC Input I:1/3 is
Fuel 2 Temperature High High heavy oil temperature energized (Fuel 2 is Check oil temperature.
Selected)
PLC Input
Fuel 2 Pressure Low Low fuel oil pressure Check oil pressure.
I:1/4 is energized
PLC Input I:1/5 is
Fuel 2 Pressure High High fuel oil pressure Check oil pressure.
energized
Fuel oil gun is not in PLC Input I:1/6 is
Oil Drawer Switch Not Made Check oil gun position.
position energized
PLC Input I:1/7 is
Atomizing Air Pressure Low Low atomizing air pressure Check atomizing air compressor
energized
1. Check for proper alarm setting.
Flue gas temperature I:2/1
High flue gas temperature 2. Deposits on the pressure vessel
Stack Temperature High Alarm is above high temperature
at the boiler outlet. surface.
alarm setting.
3. Faulty temperature sensor.
Flue gas temperature I:2/ 1. Check for proper shutdown setting.
Stack Temperature High High flue gas temperature 1) is above high 2. Deposits on the pressure vessel
Shutdown at the boiler outlet. temperature shutdown surface.
setting 3. Faulty temperature sensor.
PLC Input I:1/13 is 1. Job Specific User defined alarm.
Aux 1 – “User Defined Alarm”
energized 2. Defined on system config screen
PLC Input I:1/14 is 1. Job Specific User defined alarm.
Aux 2 – “User Defined Alarm”
energized 2. Defined on system config screen
PLC Input I:1/15 is 1. Job Specific User defined alarm.
Aux 3 – “User Defined Alarm”
energized 2. Defined on system config screen

Difference between 1. Check air damper for binding.

Air/xxx Actuator Position Combustion air actuator commanded and actual 2. Check alignment.
Deviation failed to go to position position is not within 3. Check wiring connections.
acceptable limits. 4. Replace actuator.

1. Check air damper for binding.

2. Check alignment.
Air actuator position Actuator feedback signal 3. Check wiring connections.
Air/xxx Actuator Feedback Low
feedback is low is lower than -2.0% 4. Re-commission actuator (Fuel curve
will be lost).
5. Replace actuator

6-8 Part No. 750-366

Hawk 1000 Section 6 — Diagnostics and Troubleshooting

6.3 PLC Status

The L24E has a bank of multi-state LEDs to indicate the controller’s operating
status and communication activities. See tables below.

Table 1: 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 2: PLC Communication LEDs

Indicator Status Description

Ethernet Network Off The port is not initialized; it does not have an IP address and is operating in BOOTP or DHCP
Status (NS) 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.

Part No. 750-366 6-9

Section 6 — Diagnostics and Troubleshooting Hawk 1000

Table 2: PLC Communication LEDs

Ethernet Link Sta- Off One of the following conditions exists:

tus (LINK 1/LINK 2) • No link.
• Port administratively disabled.
• Port disabled because rapid ring fault condition was detected (LINK2).

Green One of the following conditions exists:

• A 100 Mbps link (half- or full-duplex) exists, no activity.
• A 10 Mbps link (half- or full-duplex) exists, no activity.
• Ring network is operating normally and the controller is the active supervisor.
• Ring network has encountered a rare partial network fault and the controller is the active
supervisor.

Flashing green One of the following conditions exists:

• A 100 Mbps link exists and there is activity.
• A 10 Mbps link exists and there is activity.

SD Card Activity Off There is no activity to the SD card.

(SD) 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.

6-10 Part No. 750-366

 Section 7
Parts
PLC, I/O, HMI
Qty Part Number Description
1 880-06780-000 Hawk 1000 Kit
1 833-10039-000 PLC Processor
1 833-06001-000 6 Inch PV+ 7 Touch Screen
1 833-02842-000 Digital Input Module
1 833-02872-000 Relay Module
1 833-03099-000 Modbus Module SM2
2 826-00111-000 Ethernet Cable
1 832-03957-000 Power Supply120 Watt
1 832-02037-000 Power Supply 240 Watt use w/ CB O2 Trim

ACTUATORS
Qty Part Number Description
1 945-00259-000 Modbus FX04-1, 3 ft-lb (4 N-m)
(Use on Fuel and FGR valves, except in High Torque applications)
1 945-00260-000 Modbus FX20-1, 15 ft-lb (20 N-m)
(Use On Combustion Air Damper, except in High Torque applications)
1 945-00261-000 Modbus FX50-1, 37 ft-lb (50 N-m)
600” 826-00205-000 Cable, 5 conductor,18 AWG
826-00206-000 Connector, female, straight, 7/8” screw connection - Two required per actuator

MISC.
Qty Part Number Description
1 833-02835-000 1769-IF4 Analog Current Input Module (req. w/ O2 Trim, VFD, or Combustion Air Temp option)

1 833-10116-000 9300-ENA Ethernet Appliance Router

1 817-05166-000 Temperature Sensor, 8" Probe, -50-900 Deg F

1 833-09181-000 Ethernet Switch, Rockwell Stratix 5 Port, 1783-US05T

1 833-09163-000 Ethernet Switch, Rockwell Stratix, 8 Port, 1783-US08T
1
1 817-05166-000 Temperature Sensor, 8" Probe, -50-900 Deg F
1 008-02998-000 Transmitter mounting, Outdoor Reset

1 836-00627-000 Bundled Kit - Gas Oil Selector

www.cleaverbrooks.com
Section 7 — Parts Hawk 1000

FSG
Qty Part Number Description
880-02117-000 CB-780E w / IR Scanner Kit
1 833-03517-000 CB-780E Programmer
1 833-02725-000 Wiring Sub-Base
1 833-03495-000 Infared Amplifier
1 833-02730-000 Purge Timer Card
1 817-04133-000 Scanner IR 817-1742
880-02118-000 CB-780E w / UV Scanner Kit
1 833-03517-000 CB-780E Programmer
1 833-02725-000 Wiring Sub-Base
1 833-02724-000 U.V. Amplifier
1 833-02730-000 Purge Timer Card
1 817-01743-000 Flame Detector UV
880-02097-000 CB-120E w / IR Scanner Kit
1 833-03708-000 Chassis/Amplifier
1 833-03153-000 Wiring Sub-Base open with terminal block
1 833-03143-000 Programmer
1 833-03151-000 Display
1 833-03516-000 ED-512 communications cable 4 foot long
1 817-01933-000 IR Scanner 817-2261
880-02096-000 CB-120E w / UV Scanner Kit
1 833-03135-000 Chassis/Amplifier
1 833-03153-000 Wiring Sub-Base open with terminal block
1 833-03143-000 Programmer
1 833-03151-000 Display
1 833-03516-000 ED-512 communications cable 4 foot long
1 817-02262-000 UV Detector

STEAM TRANSMITTERS
Qty Part Number Description
1 817-04866-000 E&H PMC131-A22F1Q4H
1 817-00001-000 E&H PMC131-A22F1Q4N
1 817-04867-000 E&H PMC131-A22F1Q4R
1 817-09908-000 E&H PMC131-A22F1Q4S
1 817-09909-000 E&H PMC131-A22F1Q4T
Steam Transmitters (Optional)
1 817-04873-000 PMP51-1CQW9/0 (includes Isolation Valve)
1 817-00002-000 PMP51-1R5E5/0 (includes Isolation Valve)
1 817-04874-000 PMP51-1JAN0/0 (includes Isolation Valve)
1 817-04875-000 PMP51-E9K7/115 (includes Isolation Valve)
1 817-04876-000 PMP51-E9K7/101 (Specify Range) (includes Valve)
1 817-04877-000 PMP51-E9K7/139 (Specify Range) (includes Valve)
1 817-04878-000 PMP51-E9K7/125 (Specify Range) (includes Valve)
1 817-09768-000 PMP51-E9K7/142 (includes Isolation Valve)

1 817-05429-000 St boiler shell temp - NON HART 2.5" Immersion Length Carbon Steel Thermowell, no LCD Display
1 817-05430-000 St boiler shell temp - HART 2" Immersion Length Carbon Steel Thermowell, LCD Display

7-2 Part No. 750-366

Hawk 1000 Section 7 — Parts

HOT WATER
Qty Part Number Description
1 817-05431-000 4.5" Thermowell, Range -50 to 900 F no LCD display
1 817-05432-000 4.5" Thermowell, Range -50 to 900 F LCD display
1 817-09778-000 6" Thermowell, Range -50 to 900 F
1 817-05434-000 4.5" Thermowell, Range 50 to 300 F no LCD display
1 817-05435-000 4.5" Thermowell, Range 50 to 300 F LCD display
1 817-05436-000 4.5" Thermowell, Range 50 to 500 F no LCD display
1 817-05437-000 4.5" Thermowell, Range 50 to 500 F LCD display
1 817-05438-000 6" Thermowell, Range 50 to 500 F

O2 TRIM
Qty Part Number Description
O2 Monitoring Only or Air Trim
1 985-00130-000 O2 Probe and Analyzer
1 656-07576-000
1 817-05166-000 E&H, TH11-B8CBBA1AK4, NON HART, 8" Probe, -50-900 Deg F

622-00027-000 O2 Monitoring Only or Air Trim

1 880-01847-000 ECM controller with NTK Wide Band Sensor and Cable Harness
1 817-05166-000 E&H, TH11-B8CBBA1AK4, NON HART, 8" Probe, -50-900 Deg F
1 040-00735-000 O2 Sampling Probe Housing Assembly
1 832-02404-00 O2 Trim Power Supply120 Watt

Part No. 750-366 7-3

Section 7 — Parts Hawk 1000

7-4 Part No. 750-366

 Hawk 1000 APPENDIX A

APPENDIX A — HAWK 1000 MASTER TAG LIST

Grayed out items not applicable to Hawk 1000

FPC-N34 Modbus FPC-N35

PLC Point Name BACnet BACnet N2 Data N2 Point Modbus Data Type Lon Name Lon SNVT Type
Tagname Data Type Object Id Type Address Register
AB[0].0 Drive Fault BI 1 DI 1 10001 Boolean nvoDrvFlt_XXX SNVT_switch
AB[0].1 Modbus Comm Error BI 2 DI 2 10002 Boolean nvoModCmEr_XXX SNVT_switch
AB[0].2 Lo Water BI 3 DI 3 10003 Boolean nvoLoater_XXX SNVT_switch
AB[0].3 Burner Control Alm BI 4 DI 4 10004 Boolean nvoBrnCtrAlm_XXX SNVT_switch
AB[0].4 Boiler Limits Open BI 5 DI 5 10005 Boolean nvoBlrLimOpn_XXX SNVT_switch
AB[0].5 Hi Stack Temp Alm BI 6 DI 6 10006 Boolean nvoHiStkTpAl_XXX SNVT_switch
AB[0].6 Hi Stack Temp Shutdown BI 7 DI 7 10007 Boolean nvoHiStTpShd_XXX SNVT_switch
AB[0].7 External Interlock BI 8 DI 8 10008 Boolean nvoExtIntrlk_XXX SNVT_switch
AB[0].8 I/O module fault BI 9 DI 9 10009 Boolean nvoIOModFlt_XXX SNVT_switch
AB[0].9 Steam Sensor Fail BI 10 DI 10 10010 Boolean nvoStmSenFl_XXX SNVT_switch
AB[0].10 Air Actuator Out Of Pos Alm BI 11 DI 11 10011 Boolean nvoArAcPosAl_XXX SNVT_switch
AB[0].11 NG Actuator Out Of Pos Alm BI 12 DI 12 10012 Boolean nvoNGAcPosAl_XXX SNVT_switch
AB[0].12 F/A Ratio Controller Fault BI 13 DI 13 10013 Boolean nvoFARatCtFl_XXX SNVT_switch
AB[0].13 No Fuel Selected BI 14 DI 14 10014 Boolean nvoNoFlSel_XXX SNVT_switch
AB[0].14 Lo ControlLogix Battery BI 15 DI 15 10015 Boolean nvoLoPLCBat_XXX SNVT_switch
AB[0].15 Non Recycle Limit Relay Fail BI 16 DI 16 10016 Boolean nvoNoRcLmRlF_XXX SNVT_switch
AB[1].0 Recyle Limit Relay Fail BI 17 DI 17 10017 Boolean nvoRecLmRlFl_XXX SNVT_switch
AB[1].1 Remote Modulation Signal Fail BI 18 DI 18 10018 Boolean nvoRemMdSgFl_XXX SNVT_switch
AB[1].2 Header Pressure Sensor Fail BI 19 DI 19 10019 Boolean nvoHdPrSnFl_XXX SNVT_switch
AB[1].3 Temperature Channel 0-5 Failure BI 20 DI 20 10020 Boolean nvoTpCh0_5Fl_XXX SNVT_switch
AB[1].4 Lo O2 Alm BI 21 DI 21 10021 Boolean nvoLoO2Alm_XXX SNVT_switch
AB[1].5 Hi Limit Alm BI 22 DI 22 10022 Boolean nvoHiLimAlm_XXX SNVT_switch
AB[1].6 ALWCO BI 23 DI 23 10023 Boolean nvoALWCO_XXX SNVT_switch
AB[1].7 Lo Gas Pressure/Lo Oil Temp BI 24 DI 24 10024 Boolean nvoLoGsPrOTp_XXX SNVT_switch
AB[1].8 Hi Gas Pressure/Hi Oil Temp BI 25 DI 25 10025 Boolean nvoHiGsPrOTp_XXX SNVT_switch
AB[1].9 Lo Oil Pressure BI 26 DI 26 10026 Boolean nvoLoOilPrs_XXX SNVT_switch
AB[1].10 Hi Oil Pressure BI 27 DI 27 10027 Boolean nvoHiOilPrs_XXX SNVT_switch
AB[1].11 Oil Drawer Switch Not Made BI 28 DI 28 10028 Boolean nvoOilDrwrSw_XXX SNVT_switch
AB[1].12 Lo Atomizing Air Pressure BI 29 DI 29 10029 Boolean nvoLoAtmArPr_XXX SNVT_switch
AB[1].13 Lo Combustion Air Pressure BI 30 DI 30 10030 Boolean nvoLoComArPr_XXX SNVT_switch
AB[1].14 AUX Alm 1 BI 31 DI 31 10031 Boolean nvoAUXAlm1_XXX SNVT_switch
AB[1].15 AUX Alm 2 BI 32 DI 32 10032 Boolean nvoAUXAlm2_XXX SNVT_switch
AB[2].0 Blower On BI 33 DI 33 10033 Boolean nvoBlwOn_XXX SNVT_switch
AB[2].1 Purge Input BI 34 DI 34 10034 Boolean nvoPrgIn_XXX SNVT_switch
AB[2].2 Release To Modulate Input BI 35 DI 35 10035 Boolean nvoRel2ModIn_XXX SNVT_switch
AB[2].3 Lo Fire Switch BI 36 DI 36 10036 Boolean nvoLoFirSw_XXX SNVT_switch
AB[2].4 Hi Fire Switch BI 37 DI 37 10037 Boolean nvoHiFirSw_XXX SNVT_switch
AB[2].5 Ready to start/Limits Closed BI 38 DI 38 10038 Boolean nvoRdy2Str_XXX SNVT_switch
AB[2].6 External Start Interlock BI 39 DI 39 10039 Boolean nvoExtStInlk_XXX SNVT_switch
AB[2].7 ALFCO BI 40 DI 40 10040 Boolean nvoALFCO_XXX SNVT_switch
AB[2].8 Pilot BI 41 DI 41 10041 Boolean nvoPilot_XXX SNVT_switch
AB[2].9 Main Fuel Valve Open BI 42 DI 42 10042 Boolean nvoMnFlVlvOp_XXX SNVT_switch
AB[2].10 Fuel 1 Selected BI 43 DI 43 10043 Boolean nvoFl1Sel_XXX SNVT_switch
AB[2].11 Fuel 2 Selected BI 44 DI 44 10044 Boolean nvoFl2Sel_XXX SNVT_switch
AB[2].12 Heart Beat To BMS BI 45 DI 45 10045 Boolean nvoHrtBtBMS_XXX SNVT_switch
AB[2].13 LWCO Shutdown BI 46 DI 46 10046 Boolean nvoLWCOShdn_XXX SNVT_switch
AB[2].14 Remote Enable Input BI 47 DI 47 10047 Boolean nvoRmEnblInp_XXX SNVT_switch
AB[2].15 Burner Switch BI 48 DI 48 10048 Boolean nvoBrnSw_XXX SNVT_switch
AB[3].0 Recycle Limit Relay BI 49 DI 49 10049 Boolean nvoRecLimRel_XXX SNVT_switch
AB[3].1 External Device Start BI 50 DI 50 10050 Boolean nvoExtDevSt_XXX SNVT_switch
AB[3].2 Non Recycle Limit Relay BI 51 DI 51 10051 Boolean nvoNoRecLmRl_XXX SNVT_switch
AB[3].3 Drive to Lo Fire (FARC) BI 52 DI 52 10052 Boolean nvoDrv2LoFir_XXX SNVT_switch
AB[3].4 Start Slave Blr (2 Blr LL) BI 53 DI 53 10053 Boolean nvoStrtSlvBl_XXX SNVT_switch
AB[3].5 Load Demand Output BI 54 DI 54 10054 Boolean nvoLdDemOut_XXX SNVT_switch
AB[3].6 Alm Output BI 55 DI 55 10055 Boolean nvoAlmOut_XXX SNVT_switch
AB[3].7 Boiler Ready (LL) BI 56 DI 56 10056 Boolean nvoBlrRdyLL_XXX SNVT_switch
AB[3].8 Boiler Load Demand BI 57 DI 57 10057 Boolean nvoBlrLdDem_XXX SNVT_switch
AB[3].9 Firing Rate Remote/Llag BI 58 DI 58 10058 Boolean nvoFrRatRmLL_XXX SNVT_switch
AB[3].10 Firing Rate Manual BI 59 DI 59 10059 Boolean nvoFirRatMan_XXX SNVT_switch
AB[3].11 Firing Rate Auto BI 60 DI 60 10060 Boolean nvoFrRatAuto_XXX SNVT_switch
AB[3].12 Hot Stand By BI 61 DI 61 10061 Boolean nvoHotStndBy_XXX SNVT_switch
AB[3].13 Warm Up BI 62 DI 62 10062 Boolean nvoWarmUp_XXX SNVT_switch
AB[3].14 Fuel 3 Selected BI 63 DI 63 10063 Boolean nvoFl3Sel_XXX SNVT_switch
AB[3].15 Aux Alm 3 BI 64 DI 64 10064 Boolean nvoAuxAlm3_XXX SNVT_switch
AB[4].0 Steam or Hot Water 1 = Steam BI 65 DI 65 10065 Boolean nvoStm_HWtr_XXX SNVT_switch
AB[4].1 Level Master Present BI 66 DI 66 10066 Boolean nvoLvlMstPrs_XXX SNVT_switch
AB[4].2 Variable Speed Drive Present BI 67 DI 67 10067 Boolean nvoVarSpDrPr_XXX SNVT_switch
AB[4].3 Economizer Present BI 68 DI 68 10068 Boolean nvoEcPrs_XXX SNVT_switch
AB[4].4 Combustion Air Temp Present BI 69 DI 69 10069 Boolean nvoCmArTpPrs_XXX SNVT_switch
AB[4].5 Economizer Inlet FW Sensor Present BI 70 DI 70 10070 Boolean nvoEInFwSnPr_XXX SNVT_switch
AB[4].6 O2 Analyzer Present BI 71 DI 71 10071 Boolean nvoO2AnlzrPr_XXX SNVT_switch
AB[4].7 Feedwater or Return Temp Present BI 72 DI 72 10072 Boolean nvoFdWRtTpPr_XXX SNVT_switch
AB[4].8 Outdoor Reset Selected BI 73 DI 73 10073 Boolean nvoOutResSel_XXX SNVT_switch
AB[4].9 Parallel Posing Selected BI 74 DI 74 10074 Boolean nvoParPosSel_XXX SNVT_switch
AB[4].10 Two Boiler Lead Lag Master Select BI 75 DI 75 10075 Boolean nvo2BLLMstSl_XXX SNVT_switch
AB[4].11 Two Boiler Lead Lag Slave Select BI 76 DI 76 10076 Boolean nvo2BLLSlvSl_XXX SNVT_switch

Part No. 750-366 A-1

APPENDIX A Hawk 1000

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

AB[4].13 Hot Stand By Select BI 78 DI 78 10078 Boolean nvoHotStbySl_XXX SNVT_switch
AB[4].14 Dual Setpoint Select BI 79 DI 79 10079 Boolean nvoDualSPSel_XXX SNVT_switch
AB[4].15 Slot 8 Ch 0 Analog Input Selected BI 80 DI 80 10080 Boolean nvoSlCh0AISl_XXX SNVT_switch
AB[5].0 Slot 8 Ch 1 Analog Input Selected BI 81 DI 81 10081 Boolean nvoSlCh1AISl_XXX SNVT_switch
AB[5].1 Slot 8 Ch 2 Analog Input Selected BI 82 DI 82 10082 Boolean nvoSlCh2AISl_XXX SNVT_switch
AB[5].2 Slot 8 Ch 3 Analog Input Selected BI 83 DI 83 10083 Boolean nvoSlCh3AISl_XXX SNVT_switch
AB[5].3 Honeywell or Fireye 1 = Fireye BI 84 DI 84 10084 Boolean nvoHnywFreye_XXX SNVT_switch
AB[5].4 Hi Water Alm BI 85 DI 85 10085 Boolean nvoHiWtrAlm_XXX SNVT_switch
AB[5].5 Oil Actuator Out Of Pos Alm BI 86 DI 86 10086 Boolean nvoOlAcPsAlm_XXX SNVT_switch
AB[5].6 FGR Actuator Out Of Pos Alm BI 87 DI 87 10087 Boolean nvoFGRAcPsAl_XXX SNVT_switch
AB[5].7 Air Actuator Feedback Fail Lo Alm BI 88 DI 88 10088 Boolean nvoAAcFdLoAl_XXX SNVT_switch
AB[5].8 Air Actuator Feedback Fail Hi Alm BI 89 DI 89 10089 Boolean nvoAAcFdHiAl_XXX SNVT_switch
AB[5].9 NG Actuator Feedback Fail Lo Alm BI 90 DI 90 10090 Boolean nvoNGAFdLoAl_XXX SNVT_switch
AB[5].10 NG Actuator Feedback Fail Hi Alm BI 91 DI 91 10091 Boolean nvoNGAFdHiAl_XXX SNVT_switch
AB[5].11 Oil Actuator Feedback Fail Lo Alm BI 92 DI 92 10092 Boolean nvoOilFdLoAl_XXX SNVT_switch
AB[5].12 Oil Actuator Feedback Fail Hi Alm BI 93 DI 93 10093 Boolean nvoOilFdHiAl_XXX SNVT_switch
AB[5].13 FGR Actuator Feedback Fail Lo Alm BI 94 DI 94 10094 Boolean nvoFGRFdLoAl_XXX SNVT_switch
AB[5].14 FGR Actuator Feedback Fail Hi Alm BI 95 DI 95 10095 Boolean nvoFGRFdHiAl_XXX SNVT_switch
AB[5].15 VSD Deviation Alm BI 96 DI 96 10096 Boolean nvoVSDDevAlm_XXX SNVT_switch
AB[6].0 Increase MSG Register Size Bit BI 97 DI 97 10097 Boolean nvoIncMSGReg_XXX SNVT_switch
AB[6].1 Air/Fuel Deviation Alm BI 98 DI 98 10098 Boolean nvoArFlDevAl_XXX SNVT_switch
AB[6].2 2nd Stage CEC Economizer Selected BI 99 DI 99 10099 Boolean nvo2StCECEcS_XXX SNVT_switch
AB[6].3 2 Brl L-L Slave Boiler IP Not Set BI 100 DI 100 10100 Boolean nvoFl3AcPsAl_XXX SNVT_switch
AB[6].4 2 Brl L-L Slave Boiler Comm Error BI 101 DI 101 10101 Boolean nvoFl3AFdLoA_XXX SNVT_switch
AB[6].5 2 Brl L-L Slave Boiler Not Capable of Comm BI 102 DI 102 10102 Boolean nvoFl3AFdHiA_XXX SNVT_switch
Control
AB[6].6 Stack Pressure Input Fail BI 103 DI 103 10103 Boolean nvoStkPrInFl_XXX SNVT_switch
AB[6].7 Hi Stack Pressure Alm BI 104 DI 104 10104 Boolean nvoHiStkPrAl_XXX SNVT_switch
AB[6].8 Stack Damper Not Open Alm BI 105 DI 105 10105 Boolean nvoStDpNtOAl_XXX SNVT_switch
AB[6].9 O2 Calibration Failed BI 106 DI 106 10106 Boolean nvoO2ClRtFld_XXX SNVT_switch
AB[6].10 Lo Steam Pressure/Water Temp Alm BI 107 DI 107 10107 Boolean nvoLoStPWTAl_XXX SNVT_switch
AB[6].11 Processor Test Fail Alm BI 108 DI 108 10108 Boolean nvoPrTstFlAl_XXX SNVT_switch
AB[6].12 O2 Trim Internal Alm BI 109 DI 109 10109 Boolean nvoO2TrmInAl_XXX SNVT_switch
AB[6].13 Firetube or Flextube 1 = Flextube BI 110 DI 110 10110 Boolean nvoFir_FlxTb_XXX SNVT_switch
AB[6].14 Reserved for Cleaver Brooks BI 111 DI 111 10111 Boolean nvoAB_6_14_XXX SNVT_switch
AB[6].15 VSD Limits Internal Alm BI 112 DI 112 10112 Boolean nvoVSDLmInAl_XXX SNVT_switch
AB[7].0 Gas Actuator 2 Out Of Pos Alm BI 113 DI 113 10113 Boolean nvoGsAc2PsAl_XXX SNVT_switch
AB[7].1 Gas Actuator 2 Feedback Fail Lo Alm BI 114 DI 114 10114 Boolean nvoGsAc2LoAl_XXX SNVT_switch
AB[7].2 Gas Actuator 2 Feedback Fail Hi Alm BI 115 DI 115 10115 Boolean nvoGsAc2HiAl_XXX SNVT_switch
AB[7].3 Actuator Modbus Communication Error BI 116 DI 116 10116 Boolean nvoAcModCmEr_XXX SNVT_switch
AB[7].4 Air Actuator Modbus Comm Error Node 1 BI 117 DI 117 10117 Boolean nvoAAcMdCEr1_XXX SNVT_switch
AB[7].5 Gas Actuator Modbus Comm Error Node 2 BI 118 DI 118 10118 Boolean nvoGsAMdCEr2_XXX SNVT_switch
AB[7].6 Gas Act 2 Modbus Comm Error Node 3 BI 119 DI 119 10119 Boolean nvoGsA2MdCE3_XXX SNVT_switch
AB[7].7 Oil Actuator Modbus Comm Error Node 5 BI 120 DI 120 10120 Boolean nvoOAcMdCEr5_XXX SNVT_switch
AB[7].8 FGR Actuator Modbus Comm Error Node 7 BI 121 DI 121 10121 Boolean nvoFGRAMdCE7_XXX SNVT_switch
AB[7].9 Reserved BI 122 DI 122 10122 Boolean nvoAB_7_9_XXX SNVT_switch
AB[7].10 Reserved BI 123 DI 123 10123 Boolean nvoAB_7_10_XXX SNVT_switch
AB[7].11 2nd Stg Outlet Wtr Temp Sensor Failed BI 124 DI 124 10124 Boolean nvo2StOtWTSF_XXX SNVT_switch
AB[7].12 Wtr Temp Second Stg Out Hi BI 125 DI 125 10125 Boolean nvoWT2StOtHi_XXX SNVT_switch
AB[7].13 Air Actuator Man Override Btn Press BI 126 DI 126 10126 Boolean nvoAAcMnOBPr_XXX SNVT_switch
AB[7].14 Gas Actuator 1 Man Override Btn Press BI 127 DI 127 10127 Boolean nvoGAc1MOBPr_XXX SNVT_switch
AB[7].15 Gas Actuator 2 Man Override Btn Press BI 128 DI 128 10128 Boolean nvoGAc2MOBPr_XXX SNVT_switch
AB[8].0 Oil Actuator Man Override Btn Press BI 129 DI 129 10129 Boolean nvoOAcMnOBPr_XXX SNVT_switch
AB[8].1 FGR Actuator Man Override Btn Press BI 130 DI 130 10130 Boolean nvoFGRAMnOBP_XXX SNVT_switch
AB[8].2 Fuel 3 Act 1 Man Override Btn Press BI 131 DI 131 10131 Boolean nvoFl3A1MOBP_XXX SNVT_switch
AB[8].3 Fuel 3 Act 2 Man Override Btn Press BI 132 DI 132 10132 Boolean nvoFl3A2MOBP_XXX SNVT_switch
AB[8].4 Communication from BMS Failed BI 133 DI 133 10133 Boolean nvoComBMSFld_XXX SNVT_switch
AB[8].5 Combustion Air Pressure Hi BI 134 DI 134 10134 Boolean nvoComArPrHi_XXX SNVT_switch
AB[8].6 Wtr FLo Lo BI 135 DI 135 10135 Boolean nvoWtrFloLo_XXX SNVT_switch
AB[8].7 Wtr Level Signal Failed BI 136 DI 136 10136 Boolean nvoWtLvSgFld_XXX SNVT_switch
AB[8].8 Remote Setpoint Signal Failed BI 137 DI 137 10137 Boolean nvoRmSPSgFld_XXX SNVT_switch
AB[8].9 Lo O2 Shutdown BI 138 DI 138 10138 Boolean nvoLoO2Shdn_XXX SNVT_switch
AB[8].10 Air Actuator Fault BI 139 DI 139 10139 Boolean nvoAirAcFlt_XXX SNVT_switch
AB[8].11 Fuel 1 Actuator 1 Fault BI 140 DI 140 10140 Boolean nvoFl1Ac1Flt_XXX SNVT_switch
AB[8].12 Fuel 1 Actuator 2 Fault BI 141 DI 141 10141 Boolean nvoFl1Ac2Flt_XXX SNVT_switch
AB[8].13 Fuel 2 Actuator 1 Fault BI 142 DI 142 10142 Boolean nvoFl2Ac1Flt_XXX SNVT_switch
AB[8].14 Fuel 2 Actuator 2 Fault BI 143 DI 143 10143 Boolean nvoFl2Ac2Flt_XXX SNVT_switch
AB[8].15 FGR Actuator Fault BI 144 DI 144 10144 Boolean nvoFGRAcFlt_XXX SNVT_switch
AB[9].0 Fuel 2 Actuator 2 Pos Deviation BI 145 DI 145 10145 Boolean nvoFl2Ac2PsD_XXX SNVT_switch
AB[9].1 Fuel 2 Actuator 2 Feedback Lo BI 146 DI 146 10146 Boolean nvoFl2Ac2FLo_XXX SNVT_switch
AB[9].2 Fuel 2 Actuator 2 Feedback Hi BI 147 DI 147 10147 Boolean nvoFl2Ac2FHi_XXX SNVT_switch
AB[9].3 Fuel 2 Actuator 2 Man PB Press BI 148 DI 148 10148 Boolean nvoF2A2MnPBP_XXX SNVT_switch
AB[9].4 VFD Feedback Lo BI 149 DI 149 10149 Boolean nvoVFDFdbkLo_XXX SNVT_switch
AB[9].5 VFD Feedback Hi BI 150 DI 150 10150 Boolean nvoVFDFdbkHi_XXX SNVT_switch
AB[9].6 Master PIDE Instruction Fault BI 151 DI 151 10151 Boolean nvoMPIDEInFl_XXX SNVT_switch
AB[9].7 FGEN Fault BI 152 DI 152 10152 Boolean nvoFGENFlt_XXX SNVT_switch
AB[9].8 Outdoor Temp/Retrun Temp Sensor Failed BI 153 DI 153 10153 Boolean nvoOTmpRTpFl_XXX SNVT_switch
AB[9].9 Combustion Air Temp Sensor Failed BI 154 DI 154 10154 Boolean nvoCmATpSnFl_XXX SNVT_switch
AB[9].10 O2 Sensor Fault BI 155 DI 155 10155 Boolean nvoO2SenFlt_XXX SNVT_switch
AB[9].11 Fuel2 Act 2 Modbus Comm Error Node 6 BI 156 DI 156 10156 Boolean nvoAB_9_11_XXX SNVT_switch
AB[9].12 Fault Present BI 157 DI 157 10157 Boolean nvoAB_9_12_XXX SNVT_switch
AB[9].13 AB[9]13 BI 158 DI 158 10158 Boolean nvoAB_9_13_XXX SNVT_switch
AB[9].14 AB[9]14 BI 159 DI 159 10159 Boolean nvoAB_9_14_XXX SNVT_switch
AB[9].15 Hawk 1000 system BI 160 DI 160 10160 Boolean nvoH1000Sys_XXX SNVT_switch

A-2 Part No. 750-366

Hawk 1000 APPENDIX A

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

AR[1] Combustion Air Fan Speed AI 2 AI 2 30003 Real nvoCmArFnSpd_XXX SNVT_count_f
AR[2] AR[2] AI 3 AI 3 30005 Real nvoAR_2__XXX SNVT_count_f
AR[3] Boiler Efficiency AI 4 AI 4 30007 Real nvoBlrEff_XXX SNVT_lev_percent
AR[4] Firing Rate AI 5 AI 5 30009 Real nvoFirRat_XXX SNVT_lev_percent
AR[5] O2 Level AI 6 AI 6 30011 Real nvoO2Lvl_XXX SNVT_lev_percent
AR[6] SP Steam Pressure/Wtr Temp AI 7 AI 7 30013 Real nvoSPStPWtTp_XXX SNVT_count_f
AR[7] Wtr Level AI 8 AI 8 30015 Real nvoWtrLvl_XXX SNVT_press_f
AR[8] Steam Pressure or Hot Wtr Temp AI 9 AI 9 30017 Real nvoStPrHWTmp_XXX SNVT_count_f
AR[9] AR[9] AI 10 AI 10 30019 Real nvoAR_9_XXX SNVT_count_f
AR[10] Stack Temp Before Economizer AI 11 AI 11 30021 Real nvoStkTpBfEc_XXX SNVT_temp_p
AR[11] Combustion Air Temp AI 12 AI 12 30023 Real nvoComAirTmp_XXX SNVT_temp_p
AR[12] Wtr Temp Shell/Outdoor Temp AI 13 AI 13 30025 Real nvoWtTpShl_XXX SNVT_temp_p
AR[13] FeedWtr Temp/Econ Wtr Out Temp AI 14 AI 14 30027 Real nvoFdWtTp_XXX SNVT_temp_p
AR[14] Stack Temp After Econ/Return HW AI 15 AI 15 30029 Real nvoStkTmpEco_XXX SNVT_temp_p
AR[15] Economizer Wtr In Temp AI 16 AI 16 30031 Real nvoEcWtInTmp_XXX SNVT_temp_p
AR[16] AI Slot8 Ch0 Value 2Stg Econ Temp IN AI 17 AI 17 30033 Real nvoAISlCh0Vl_XXX SNVT_count_f
AR[17] AI Slot8 Ch1 Value 2Stg Econ Temp OUT AI 18 AI 18 30035 Real nvoAISlCh1Vl_XXX SNVT_count_f
AR[18] AI Slot8 Ch2 Value (EU) AI 19 AI 19 30037 Real nvoAISlCh2Vl_XXX SNVT_count_f
AR[19] AI Slot8 Ch3 Value (EU) AI 20 AI 20 30039 Real nvoAISlCh3Vl_XXX SNVT_count_f
AR[20] Safety Valve Setting or Max Wtr Temp AI 21 AI 21 30041 Real nvoSftVlvSet_XXX SNVT_count_f
AR[21] Header Pressure or Temp 2 Boiler LL AI 22 AI 22 30043 Real nvoHdPrTpBLL_XXX SNVT_count_f
AR[22] SP 2 Boiler LL AI 23 AI 23 30045 Real nvoSP2BlrLL_XXX SNVT_count_f
AR[23] Boiler Off Point AI 24 AI 24 30047 Real nvoBlrOffPt_XXX SNVT_count_f
AR[24] Boiler On Point AI 25 AI 25 30049 Real nvoBlrOnPt_XXX SNVT_count_f
AR[25] Condensate Return Valve Output Command AI 26 AI 26 30051 Real nvoCdRtVOtCm_XXX SNVT_lev_percent
AR[26] Makeup Bypass Valve Output Command AI 27 AI 27 30053 Real nvoMkByVOtCm_XXX SNVT_lev_percent
AR[27] Slot8 Ch0 FLo Total AI 28 AI 28 30055 Real nvoSlC0FlTo_XXX SNVT_count_f
AR[28] Slot8 Ch1 FLo Total AI 29 AI 29 30057 Real nvoSlC1FlTo_XXX SNVT_count_f
AR[29] Slot8 Ch2 FLo Total AI 30 AI 30 30059 Real nvoSlC2FlTo_XXX SNVT_count_f
AR[30] Slot8 Ch3 FLo Total AI 31 AI 31 30061 Real nvoSlC3FlTo_XXX SNVT_count_f
AR[31] AR[31] AI 32 AI 32 30063 Real nvoAR_31_XXX SNVT_count_f
AR[32] AR[32] AI 33 AI 33 30065 Real nvoAR_32_XXX SNVT_count_f
AR[33] AR[33] AI 34 AI 34 30067 Real nvoAR_33_XXX SNVT_count_f
AR[34] AR[34] AI 35 AI 35 30069 Real nvoAR_34_XXX SNVT_count_f
AR[35] AR[35] AI 36 AI 36 30071 Real nvoAR_35_XXX SNVT_count_f
AR[36] AR[36] AI 37 AI 37 30073 Real nvoAR_36_XXX SNVT_count_f
AR[37] AR[37] AI 38 AI 38 30075 Real nvoAR_37_XXX SNVT_count_f
AR[38] AR[38] AI 39 AI 39 30077 Real nvoAR_38_XXX SNVT_count_f
AR[39] AR[39] AI 40 AI 40 30079 Real nvoAR_39_XXX SNVT_count_f
AR[40] AR[40] AI 41 AI 41 30081 Real nvoAR_40_XXX SNVT_count_f
AR[41] AR[41] AI 42 AI 42 30083 Real nvoAR_41_XXX SNVT_count_f
AR[42] AR[42] AI 43 AI 43 30085 Real nvoAR_42_XXX SNVT_count_f
AR[43] AR[43] AI 44 AI 44 30087 Real nvoAR_43_XXX SNVT_count_f
AR[44] AR[44] AI 45 AI 45 30089 Real nvoAR_44_XXX SNVT_count_f
AR[45] AR[45] AI 46 AI 46 30091 Real nvoAR_45_XXX SNVT_count_f
AR[46] AR[46] AI 47 AI 47 30093 Real nvoAR_46_XXX SNVT_count_f
AR[47] AR[47] AI 48 AI 48 30095 Real nvoAR_47_XXX SNVT_count_f
AR[48] AR[48] AI 49 AI 49 30097 Real nvoAR_48_XXX SNVT_count_f
AR[49] AR[49] AI 50 AI 50 30099 Real nvoAR_49_XXX SNVT_count_f
AI[0] Burner Control Status Line 1 Honeywell AI 52 AI 52 30102 Single Integer nvoBSt1Hnywl_XXX SNVT_count_f
AI[1] Burner Control Status Line 2 Honeywell AI 53 AI 53 30103 Single Integer nvoBSt2Hnywl_XXX SNVT_count_f
AI[2] Burner Control Status Line 1 Fireye AI 54 AI 54 30104 Single Integer nvoBSt1Freye_XXX SNVT_count_f
AI[3] Burner Control Status Line 2 Fireye AI 55 AI 55 30105 Single Integer nvoBSt2Freye_XXX SNVT_count_f
AI[4] Flame Signal Fireye AI 56 AI 56 30106 Single Integer nvoFlSgFrey_XXX SNVT_count_f
AI[5] Fuel 1Type AI 57 AI 57 30107 Single Integer nvoFl1Type_XXX SNVT_count_f
AI[6] Fuel 2 Type AI 58 AI 58 30108 Single Integer nvoFl2Type_XXX SNVT_count_f
AI[7] Fuel 3 Type AI 59 AI 59 30109 Single Integer nvoFl3Type_XXX SNVT_count_f
AI[9] Elapsed Time (First 16 Bits) AI 61 AI 61 30111 Single Integer nvoElpTm1_XXX SNVT_time_hour
AI[10] Elapsed Time (Second 16 Bits) AI 62 AI 62 30112 Single Integer nvoElpTm2_XXX SNVT_time_hour
AI[11] Number Of Cycles (First 16 Bits) AI 63 AI 63 30113 Single Integer nvoNumCyc1_XXX SNVT_count_f
AI[12] Number Of Cycles (Second 16 Bits) AI 64 AI 64 30114 Single Integer nvoNumCyc2_XXX SNVT_count_f
AI[13] AI[13] AI 65 AI 65 30115 Single Integer nvoAI_13_XXX SNVT_count_f
AI[14] AI[14] AI 66 AI 66 30116 Single Integer nvoAI_14_XXX SNVT_count_f
AD[0] Elapsed Time AI 67 AI 67 30117 Double Integer nvoElapTim_XXX SNVT_time_hour
AD[1] Number Of Cycles AI 68 AI 68 30119 Double Integer nvoNumCyc_XXX SNVT_count_f
AWB[0].0 Heart Beat From BMS BV 1 DO 1 00001 Boolean nviHtBtFrBMS_XXX SNVT_switch
AWB[0].1 Remote Start From BMS BV 2 DO 2 00002 Boolean nviRmStFrBMS_XXX SNVT_switch
AWB[0].2 AWB[0]2 BV 3 DO 3 00003 Boolean nviAWB_0_2_XXX SNVT_switch
AWB[0].3 AWB[0]3 BV 4 DO 4 00004 Boolean nviAWB_0_3_XXX SNVT_switch
AWB[0].4 AWB[0]4 BV 5 DO 5 00005 Boolean nviAWB_0_4_XXX SNVT_switch
AWB[0].5 AWB[0]5 BV 6 DO 6 00006 Boolean nviAWB_0_5_XXX SNVT_switch
AWB[0].6 AWB[0]6 BV 7 DO 7 00007 Boolean nviAWB_0_6_XXX SNVT_switch
AWB[0].7 AWB[0]7 BV 8 DO 8 00008 Boolean nviAWB_0_7_XXX SNVT_switch
AWB[0].8 AWB[0]8 BV 9 DO 9 00009 Boolean nviAWB_0_8_XXX SNVT_switch
AWB[0].9 AWB[0]9 BV 10 DO 10 00010 Boolean nviAWB_0_9_XXX SNVT_switch
AWB[0].10 AWB[0]10 BV 11 DO 11 00011 Boolean nviAWB_0_10_XXX SNVT_switch
AWB[0].11 AWB[0]11 BV 12 DO 12 00012 Boolean nviAWB_0_11_XXX SNVT_switch
AWB[0].12 AWB[0]12 BV 13 DO 13 00013 Boolean nviAWB_0_12_XXX SNVT_switch
AWB[0].13 AWB[0]13 BV 14 DO 14 00014 Boolean nviAWB_0_13_XXX SNVT_switch
AWB[0].14 AWB[0]14 BV 15 DO 15 00015 Boolean nviAWB_0_14_XXX SNVT_switch
AWB[0].15 AWB[0]15 BV 16 DO 16 00016 Boolean nviAWB_0_15_XXX SNVT_switch
AWB[1].0 AWB[1]0 BV 17 DO 17 00017 Boolean nviAWB_1_0_XXX SNVT_switch
AWB[1].1 AWB[1]1 BV 18 DO 18 00018 Boolean nviAWB_1_1_XXX SNVT_switch
AWB[1].2 AWB[1]2 BV 19 DO 19 00019 Boolean nviAWB_1_2_XXX SNVT_switch
AWB[1].3 AWB[1]3 BV 20 DO 20 00020 Boolean nviAWB_1_3_XXX SNVT_switch

Part No. 750-366 A-3

APPENDIX A Hawk 1000

AWB[1].4 AWB[1]4 BV 21 DO 21 00021 Boolean nviAWB_1_4_XXX SNVT_switch

AWB[1].5 AWB[1]5 BV 22 DO 22 00022 Boolean nviAWB_1_5_XXX SNVT_switch
AWB[1].6 AWB[1]6 BV 23 DO 23 00023 Boolean nviAWB_1_6_XXX SNVT_switch
AWB[1].7 AWB[1]7 BV 24 DO 24 00024 Boolean nviAWB_1_7_XXX SNVT_switch
AWB[1].8 AWB[1]8 BV 25 DO 25 00025 Boolean nviAWB_1_8_XXX SNVT_switch
AWB[1].9 AWB[1]9 BV 26 DO 26 00026 Boolean nviAWB_1_9_XXX SNVT_switch
AWB[1].10 AWB[1]10 BV 27 DO 27 00027 Boolean nviAWB_1_10_XXX SNVT_switch
AWB[1].11 AWB[1]11 BV 28 DO 28 00028 Boolean nviAWB_1_11_XXX SNVT_switch
AWB[1].12 AWB[1]12 BV 29 DO 29 00029 Boolean nviAWB_1_12_XXX SNVT_switch
AWB[1].13 AWB[1]13 BV 30 DO 30 00030 Boolean nviAWB_1_13_XXX SNVT_switch
AWB[1].14 AWB[1]14 BV 31 DO 31 00031 Boolean nviAWB_1_14_XXX SNVT_switch
AWB[1].15 AWB[1]15 BV 32 DO 32 00032 Boolean nviAWB_1_15_XXX SNVT_switch
AWR[0] Rem Op SP Boiler AV 1 AO 1 40001 Real nviRemOpSPBl_XXX SNVT_count_f
AWR[1] Rem Firing Rate AV 2 AO 2 40003 Real nviRemFirRat_XXX SNVT_lev_percent
AWR[2] Rem Op SP 2 boiler Lead/Lag AV 3 AO 3 40005 Real nviRmOSP2BLL_XXX SNVT_count_f
AWR[3] AWR[3] AV 4 AO 4 40007 Real nviAWR_3_XXX SNVT_count_f
AWR[4] AWR[4] AV 5 AO 5 40009 Real nviAWR_4_XXX SNVT_count_f
AWR[5] AWR[5] AV 6 AO 6 40011 Real nviAWR_5_XXX SNVT_count_f
AWR[6] AWR[6] AV 7 AO 7 40013 Real nviAWR_6_XXX SNVT_count_f
AWR[7] AWR[7] AV 8 AO 8 40015 Real nviAWR_7_XXX SNVT_count_f
AWR[8] AWR[8] AV 9 AO 9 40017 Real nviAWR_8_XXX SNVT_count_f
AWR[9] AWR[9] AV 10 AO 10 40019 Real nviAWR_9_XXX SNVT_count_f

A-4 Part No. 750-366

Hawk 1000 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. 750-366 B-1

APPENDIX B Hawk 1000

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. 750-366

Hawk 1000 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. 750-366 B-3