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

www.cleaverbrooks.com
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)