CleaverBrooks Hawk 1000 User manual

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

TO: Owners, Operators and/or Maintenance Personnel
This operating manual presents information that will help to properly operate and care for the equipment. Study its con-
tents carefully. The unit will provide good service and continued operation if proper operating and maintenance instruc-
tions are followed. No attempt should be made to operate the unit until the principles of operation and all of the
components are thoroughly understood.
It is the responsibility of the owner to train and advise not only his or her personnel, but the contractors' personnel who
are servicing, repairing, or operating the equipment, in all safety aspects.
Cleaver-Brooks equipment is designed and engineered to give long life and excellent service on the job. The electrical
and mechanical devices supplied as part of the unit were chosen because of their known ability to perform; however,
proper operating techniques and maintenance procedures must be followed at all times.
Any "automatic" features included in the design do not relieve 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
Manual Part No. 750-366
07/2013
Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative

CONTENTS
Section 1
General
Introduction .................................................................................. 1-2
System Description ........................................................................ 1-3
Hawk 1000 System Features .......................................................... 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 Component Checks ....................................................3-2
Modbus Actuator Checks ................................................................ 3-7
Section 4
System Configuration
Introduction .................................................................................4-2
Main Menu ..................................................................................4-2
Boiler Overview ............................................................................4-3
System Configuration ....................................................................4-4
Section 5
Commissioning
Commissioning the Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Setting Combustion - Parallel Positioning . . . . . . . . . . . . . . . . . . . . . 5-4
Setting Combustion - Single Point Positioning . . . . . . . . . . . . . . . . . . 5-8
Setting Combustion - Low/High/Low. . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Firing Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Section 6
Diagnostics and Troubleshooting
System Monitoring and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
PLC Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Section 7
Parts
Hawk 1000 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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Section 1
General
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hawk 1000 System Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Safety Provisions and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Burner Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Boiler Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Section 1 — General Hawk 1000
1-2 Part No. 750-366
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

Hawk 1000 Section 1 — General
Part No. 750-366 1-3
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 CB-PT 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
CB-PT Protocol Translator, CB-PTWS Protocol Translator with web server - 750-325
CB120E Burner Control - 750-264
CB780E Burner Control - 750-234
Variable Speed Drives - 750-198
O2 Trim - 750-224

Section 1 — General Hawk 1000
1-4 Part No. 750-366
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.)
• 4" 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 (local set point only)
• EtherNet communications
• Three firing modes: Single-point, parallel, or LOW-HIGH-LOW
• 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)

Hawk 1000 Section 1 — General
Part No. 750-366 1-5
1.4 Safety Provisions and Diagnostics
1.4.1 Burner Management
• Utilizes CB780E or CB120E Burner Control
• Communicates with the PLC via Modbus
• Burner Control Status, Faults and Diagnostics displayed on HMI or panel mounted burner control
• Flame condition monitoring using either IR or UV Flame Scanner
1.4.2 Boiler Controls
• Operating and Modulating Controls
• Monitors Low Water Cut-Off
• Monitors Burner Control alarm terminal
• Non-Recycle Limit Relay de-energizes on PLC system errors or faults
• Transmitter input signal out of range alarms
• Actuator Modbus communication fault diagnostics
• Password protected system configuration and system set up screens
• Alarm Management incorporated into door-mounted HMI
• Password protection of Programmable Controller Logic
• Optional Variable Frequency Drive (VFD) fault shutdown
Figure 1-4. Hawk 1000 Main Menu
Figure 1-3. CB 780E Figure 1-3. Burner Control Screen

Section 1 — General Hawk 1000
1-6 Part No. 750-366
1.5 Inputs and
Outputs
Processor 1769-L24ER-QBFC1B - Slot 0 1769
SM2
1769 IA16 Digital Input 1769 OW8I Isolated Digital Output 1769 IF4 Analog Input (Optional
with O2, VSD or Comb Air Temp)
Embedded I/O - Slot 1-3 Slot 4 Slot 5 Slot 6 Slot 7
Dig IN Dig OUT Ana IN Ana Out
High Limit Control I1/0 1 I5/0 Blower Terminal 1 O6/0 Recycle Limit (RLR) 1 I7/0 VSD Feedback 1
ALWCO I1/1 1 I5/1 Purge 1 O6/1 Start Ext. Device (FAD) 1 I7/1 O2 Signal 1
Low Fuel 1 Pressure/Low Oil Temp I1/2 1 I5/2 O2 Analyzer Status (Yokogawa) 1 O6/2 Non-Recycle Limit (NRLR) 1 I7/2 Comb Air Temp 1 High Fuel 1 Pressure/High Oil Temp I1/3 1 I5/3 VSD Status 1 O6/3 Prove Low Fire 1 I7/3 Reserved * 1
Low Fuel 2 Pressure I1/4 1 I5/4 Force to Low Fire 1 O6/4 Revert To Pilot (Fireye
CB120E only)
1
High Fuel 2 Pressure I1/5 1 I5/5 Ready To Start/ Limits Closed 1 O6/5 Prove High Fire / Open High
Fire Oil Valve 2
1
Oil Drawer Switch I1/6 1 I5/6 Ext. Device Start Interlock (FAD) 1 O6/6 Alarm Bell 1 Atomizing Air Pressure I1/7 1 I5/7 ALFCO 1 O6/7 Open High Fire Oil Valve 1 1
Combustion Air Pressure I1/8 1 I5/8 Pilot Terminal 1
High Water (ST) or Flow Sw. (HW) I1/9 1 I5/9 Main Fuel Terminal 1 VSD Bypass I1/10 1 I5/10 Fuel 1 Selected 1 High Combustion Air I1/11 1 I5/11 Fuel 2 Selected 1 Spare I1/12 1 I5/12 Burner Control Alarm Terminal 1 Auxiliary Alarm 1 I1/13 1 I5/13 Low Water Alarm 1 Auxiliary Alarm 2 I1/14 1 I5/14 Lead Boiler / Sel Rem Mod / Sel
SP
1
Auxiliary Alarm 3 I1/15 1 I5/15 Burner Switch 1 Reserved * O1/0 1
Ready for Lead/Lag O1/1 1
Spare(s) O1/2-O1/15 14 Steam Pres (ST) / Supply Temp (HW) I2/0 1 Stack Temp I2/1 1 Water Temp (ST) / Outdoor Temp (HW) / Return Temp (HW)
I2/2 1
Water Level (ST) / Rem Mod / Rem Set Point
I2/3 1
VSDControl O2/0 1
Firing Rate O2/1 1
High Speed Counter (NOT USED) Slot 3 Total 16 16 4 2 16 8 4 * Reserved for future add

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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

Section 2 — System Components Hawk 1000
2-2 Part No. 750-366
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.
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 progra m
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 conn ected
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.
Figure 2-1. Hawk 1000 Panel
1b 235
68 6
1
1a
7
9
4

Hawk 1000 Section 2 — System Components
Part No. 750-366 2-3
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.
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.
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)
The HMI displays numerous boiler parameters at a glance and provides easy menu navigation for configuring
system parameters, setting of combustion, monitoring the boiler processes, and managing and annunciating
system alarms.
The HMI communicates with the PLC via Ethernet and is
powered by a 24 VDC din-rail mounted power suppl y .
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)
Slot Module
1769-L24ER-QBFC1B Processor
0
1
2
3
4
5
6
7
Embedded Discrete Inputs/Outputs
Embedded Analog Inputs/Outputs
Embedded High Speed Counter
SM2 Modbus Module
Digital Input Module
Relay Output Module
Analog Input Module (4 ch. - optional)
BASE
UNIT

Section 2 — System Components Hawk 1000
2-4 Part No. 750-366
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 2-2. Firing Rate screen
Figure 2-3. SM2 Modbus Module

Hawk 1000 Section 2 — System Components
Part No. 750-366 2-5
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
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.
2.4.3 USB
USB communications are used to connect a laptop computer for diagnostic purposes.
Figure 2-4. L24ER Communication Ports
Ethernet ports (bottom of Base Unit)
PORT 1
PORT 2
01 2 34567
8 9 10 11 12 13 14 15
01 2 34567
8910
A0 B0 Z0
A1 B1 Z1
0 2 FUSE
13OK
11 12 13 14 15
HIGH SPEED
COUNTER
INOUT
DC
INPUT
24VDC
SINK\
SOURCE
24VDC
SOURCE
OUTPUT
DC
+24VDC COM FG
01234567
8 9 10 11 12 13 14 15
01 2 34567
8910
A0 B0 Z0
A1 B1 Z1
0 2 FUSE
13OK
11 12 13 14 15
HIGH SPEED
COUNTER
INOUT
DC
INPUT
24VDC
SINK\
SOURCE
24VDC
SOURCE
OUTPUT
DC
+24VDC COM FG
00
01
02
03
04
05
06
07
NC
+V
00
01
02
03
04
05
06
07
COM
0
COM
0
08
09
10
11
12
13
14
15
NC
+V
08
09
10
11
12
13
14
15
COM
1
COM
1
A0+
B0+
Z0+
A1+
B1+
Z1+
+V
OUT
1
OUT
0
COM COM
A0-
B0-
Z0-
A1-
B1-
Z1-
+V
0UT
3
V
in
0+
V
in
2+
V
OUT
0+
I
OUT
0+
V
OUT
1+
I
in
3+
V
in
1+
I
in
1+
I
in
1+
V
in
3+
CJC
-
CJC
+
V/I
in
1-
V/I
in
3-
V/I
in
0-
V/I
in
2-
I
in
0+
I
in
2+
OUT
2
COMCOM
DCIN HSC
DCOUT ANALOG
00:00:BC:2E:69:F6
L24ER
QBFC1B
USB
PORT

Section 2 — System Components Hawk 1000
2-6 Part No. 750-366
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:
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.
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.
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.
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

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Section 3
Hardware Checkout
Control Panel Component Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Actuator Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Setting The Modbus Node Address . . . . . . . . . . . . . . . . . . . . . . 3-9
Power/ Communications LED . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Moving The Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Section 3 — Hardware Checkout Hawk 1000
3-2 Part No. 750-366
3.1 Control Panel Component Checks
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).
The module locking levers should all be securely seated to the left.
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.
Figure 3-1. DIN rail latches
Figure 3-2. Expansion I/O Module locking levers
Important
!