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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 Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Содержание Hawk 1000

Страница 1: ...750 366 07 2013 Hawk 1000 Boiler Control Operation Manual...

Страница 2: ...m 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...

Страница 3: ...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...

Страница 4: ......

Страница 5: ...stem 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 Setti...

Страница 6: ......

Страница 7: ...eaverbrooks 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 Outpu...

Страница 8: ...able 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...

Страница 9: ...ding 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...

Страница 10: ...r 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 Se...

Страница 11: ...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...

Страница 12: ...sure 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 Pressur...

Страница 13: ...erbrooks com 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 sys...

Страница 14: ...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...

Страница 15: ...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...

Страница 16: ...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 actuator...

Страница 17: ...SB 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 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14...

Страница 18: ...cation 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 i...

Страница 19: ...nel 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 Actu...

Страница 20: ...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 an...

Страница 21: ...e tight and that field wiring terminations are completed and secure 3 1 3 SM2 Module DIP Switch Verify that the SM2 Module DIP switch setting is as shown below the top switch is to the left the bottom...

Страница 22: ...s 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 Pr...

Страница 23: ...rt No 750 366 3 5 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...

Страница 24: ...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 correctl...

Страница 25: ...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...

Страница 26: ...Section 3 Hardware Checkout Hawk 1000 3 8 Part No 750 366 Figure 3 5 SM2 wiring to actuators Figure 3 6 Actuator daisy chain w plug connections MODBUS ACTUATORS PLUG WIRED FUEL 1 ACT 1 FUEL 2 ACT 1...

Страница 27: ...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 de...

Страница 28: ...ower 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 posi...

Страница 29: ...en 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 a...

Страница 30: ...Section 3 Hardware Checkout Hawk 1000 3 12 Part No 750 366...

Страница 31: ...enu 4 2 Boiler Overview 4 3 System Configuration 4 4 Boiler Type and Media 4 6 Fuel Configuration 4 11 Flame Safeguard 4 12 Analog Inputs 4 13 Remote Modulation Remote Set Point 4 15 Actuator Selectio...

Страница 32: ...ree levels of security Operator Service and Factory Pressing a gray pushbutton will display the login entry window 4 2 Main Menu The Main Menu Figure 4 2 is the first screen to appear when power is ap...

Страница 33: ...4 3 Main Menu initial startup 4 3 Boiler Overview The Boiler Overview display Figure 4 4 serves as the main point of interface for the operator The primary purpose of the display is to monitor the cur...

Страница 34: ...st step in commissioning t h e b o i l e r is to configure the control system options On the Main Screen press System Config A warning message is displayed Press System Config again a final warning sc...

Страница 35: ...rt to Pilot Signal Select CB120E Only Analog Input I 2 2 Analog Input I 2 3 Remote Modulation Setpoint Signal Selection Dual Setpoint Selection Actuator Selection VFD Option Selection requires additio...

Страница 36: ...st step in the configuration procedure is to select the boiler media and type Any time a gray button appears a user I D and password are required for user input Pressing Boiler Media or Boiler Type wi...

Страница 37: ...word 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...

Страница 38: ...y 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 all...

Страница 39: ...ed value and press the Enter key If the entry is valid the value will be accepted and the keypad will disappear Note that all entries can be made by touching the HMI screen or by using the HMI keypad...

Страница 40: ...itter is not scalable The transmitters used must be rated to accommodate the required range If the Max Rated Temperature 250 Deg F the Supply Temp Transmitter is set to 50 300 Deg F If the Max Rated T...

Страница 41: ...e 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 select...

Страница 42: ...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 o...

Страница 43: ...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 Caution Revert to Pilot modes are to be determined in the field a...

Страница 44: ...ected it is mandatory that the Level Master is the sensor used to measure the water level Remote Set Point is not available on Low Emission boilers 60ppm 750 281 Level Master For Hot Water systems Ana...

Страница 45: ...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 wil...

Страница 46: ...arm and Limits Screen by setting the Remote Setpoint Scaling values zero and span of the remote 4 20mA signal Remote Set Point by Analog Input Signal Selection The user can select between HMI or digit...

Страница 47: ...al Set Point control This option is not allowed for low emission steam boilers 60 ppm 4 4 6 Actuator Selection FGR Actuator The FGR actuator should be selected as Yes if it is present on this system T...

Страница 48: ...ilable 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 comma...

Страница 49: ...s the speed of the combustion air fan motor for the purposes of improving boiler efficiency and reducing electrical energy consumption 4 4 8 Options Oxygen Analyzer The Oxygen O2 Analyzer See Figure 2...

Страница 50: ...guration 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 Hot Standby The Hot Standby function maintains...

Страница 51: ...re is displayed on the boiler overview screen Figure 4 21 Options When Outdoor Reset is selected the outdoor temperature and water temperature setpoints should be entered from the Setpoints screen See...

Страница 52: ...number must be entered again in order for this information to appear on the Master Panel HMI Auxiliary Alarm 1 3 If the system has auxiliary alarms the text that is displayed when the alarm is trigge...

Страница 53: ...le if this is a new system configuration or a system configuration parameter marked with an asterisk has been changed Figure 4 24 Configuration summary To complete system configuration press the Confi...

Страница 54: ...Section 4 System Configuration Hawk 1000 4 24 Part No 750 366...

Страница 55: ...or O2 Trim 5 8 Setting Combustion Low High Low 5 8 Firing Rate Screen 5 9 Alarms and Limits 5 11 Low O2 5 11 Low Steam Pressure 5 11 Mod Rate Limiter Max O2 Correct Remote Shutdown by Comms 5 12 Stack...

Страница 56: ...on Actuator for the desired actuator and read the warning screen which follows In this example we will be commissioning the air actuator Figure 5 2 Actuator commissioning NOTE Any combustion curves pr...

Страница 57: ...st 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 p...

Страница 58: ...available on the Main screen To begin the procedure press Set Combustion and observe the warning that follows Figure 5 6 Begin combustion setup Press I READ THE WARNING I AM QUALIFIED to continue An...

Страница 59: ...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 fo...

Страница 60: ...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 t...

Страница 61: ...f 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 cu...

Страница 62: ...be active Point 1 will be low fire Point 2 will be high fire 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 o...

Страница 63: ...urrent positions until moved manually by the operator using the Control Output Decrease and Increase buttons Figure 5 15 In Automatic mode control output is based on demand the actuators will be posit...

Страница 64: ...e 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 18 Adjust Gains Adjust Setpoint allows adjustment of Setpoint 1...

Страница 65: ...ate are not rate limited 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 Low O2...

Страница 66: ...e setting determines what the boiler will do upon a failure of remote communications shut down or remain in its last state 5 6 4 Stack Low Temp Hold This feature is only available with FGR Selectable...

Страница 67: ...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 R...

Страница 68: ...ear 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 Rever...

Страница 69: ...rol button will appear on the Main screen Figure 5 27 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...

Страница 70: ...onfiguration 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...

Страница 71: ...ch is used to provide a digital input to Boiler 2 PLC I 5 14 to designate Boiler 2 as the lead boiler With input energized set point 2 is selected Set point 2 is designated for the boiler operation wh...

Страница 72: ...ours thermal shock protection is activated For Hot Water Boilers Thermal shock protection is activated when actual water temperature is below minimum temperature 150F for Firetube 120F for FLX Maximum...

Страница 73: ...averbrooks com 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 Sta...

Страница 74: ...ol screen gives details on the installed Flame Safeguard CB780 or 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...

Страница 75: ...nal 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 conta...

Страница 76: ...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 forc...

Страница 77: ...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...

Страница 78: ...Section 6 Diagnostics and Troubleshooting Hawk 1000 6 6 Part No 750 366...

Страница 79: ...se 120 Watt for 50NM Actuator 1 848 01623 000 Centre 60x30x10 No Cut outs Conversions uses a different size 1 983 00083 000 6 Amp 1 836 00620 000 Qty 1 add another if oil heater for 6 oil is required...

Страница 80: ...er 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...

Страница 81: ...cify Range includes Valve 1 817 09768 000 PMP51 E9K7 142 includes Isolation Valve 1 817 05167 000 E H TH13 1A13X1BBA1AK NON HART 2 5 Thermowell 50 900 Deg F 1 817 05166 000 E H TH11 B8CBBA1AK4 NON HAR...

Страница 82: ...Section 7 Parts Hawk 1000 7 4 Part No 750 366...

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