Parallel Positioning Control Manual – 750-217

Table Of Contents
$35.00 U.S.
CLEAVER-BROOKS
Hawk ICS Integral
Parallel Positioning Combustion Control
Operation, Maintenance and Parts Manual
Manual Part No. 750-217
4/05
SAFETY PRECAUTIONS AND
ABBREVIATIONS
Safety Precautions
It is essential to read and understand the following safety
precautions before attempting to operate the equipment.
Failure to follow these precautions may result in damage
to equipment, serious personal injury, or death. A
complete understanding of this manual is required before
attempting to star t-up, operate or maintain the
equipment. The equipment should be operated only by
personnel who have a working knowledge and
understanding of the equipment.
The following symbols are used throughout this manual:
! WARNING
DANGER
This symbol indicates a potentially
hazardous situation which, if not
avoided, could result in serious
personal injury, or death.
AC
Alternating Current
ASTM
American Society of Testing and Materials
BHP
Boiler Horsepower
BTU
British Thermal Unit
°C
Degrees Celsius
CFH
Cubic Feet per Hour
Cu Ft
Cubic Feet
DC
Direct Current
°F
Degrees Fahrenheit
FM
Factory Mutual
FS
Flame Safeguard
ft
Feet
GPM
Gallons per Minute
Hd
Head
HT
Height
HTB
High Turndown Burner
HZ
Hertz
In H2O
Inches of Water
IRI
Industrial Risk Insurance
Lb
Pound
LWCO
Low-Water Cut-Off
M
Million
MFD
Micro-Farad
MR
Manual Reset
NEC
National Electric Code
No.
Number
pH
Measure of the degree of acid or base of a
solution
P/N
Part Number
PPM
Parts Per Million
PR
Program Relay
psi
Pounds Per Square Inch
SAE
Society of Automotive Engineers
Abbreviations
scfh
Standard Cubic Feet per Hour
Following is an explanation of the abbreviations,
acronyms, and symbols used in this manual.
T
Temperature
TC
Temperature Control
TI
Temperature Gauge
! CAUTION
DANGER
This symbol indicates a potentially hazardous situation which, if not avoided, could
result in damage to the equipment.
Note: This symbol indicates information
that is vital to the operation of this
equipment.
UL
Underwriter’s Laboratories
AC
Alternating Current
V
Volt
AR
Automatic Reset
WC
Water Column
ASME
American Society of Mechanical Engineers
WSI
Watts Per Square Inch
Hawk ICS Integral
Parallel Positioning Combustion Control
Operation, Maintenance and Parts Manual
 Cleaver-Brooks 2005
Please direct purchase orders for replacement manuals to your local Cleaver-Brooks authorized representative
Manual Part No. 750-217
Printed in U.S.A.
! WARNING
DANGER
DO NOT OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS YOU FULLY UNDERSTAND ALL
APPLICABLE SECTIONS OF THIS MANUAL.
DO NOT ALLOW OTHERS TO OPERATE, SERVICE, OR REPAIR THIS EQUIPMENT UNLESS THEY FULLY
UNDERSTAND ALL APPLICABLE SECTIONS OF THIS MANUAL.
FAILURE TO FOLLOW ALL APPLICABLE WARNINGS AND INSTRUCTIONS MAY RESULT IN SEVERE
PERSONAL INJURY OR DEATH.
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 contents carefully. The unit will provide good service and continued operation if proper operating and maintenance instructions are followed. No attempt should be made to operate the unit until the principles of operation and all of the
components are thoroughly understood. Failure to follow all applicable instructions and warnings may result in severe
personal injury or death.
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. Although these components
afford a high degree of protection and safety, operation of equipment is not to be considered free from all dangers and
hazards inherent in handling and firing of fuel.
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 instructions can replace intelligent thinking and reasoning and this manual is not intended to relieve the operating personnel of
the responsibility for proper operation. On the other hand, a thorough understanding of this manual is required before
attempting to operate, maintain, service, or repair this equipment.
Because of state, local, or other applicable codes, there are a variety of electric controls and safety devices which vary
considerably from one system to another. This manual contains information designed to show how a basic system operates.
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 to the equipment. In most cases, these malfunctions can be traced directly to carelessness and deficiencies in testing and maintenance.
It is recommended that a boiler room log or record be maintained. Recording of daily, weekly, monthly and yearly maintenance activities and recording of any unusual operation will serve as a valuable guide to any necessary investigation.
Most instances of major boiler damage are the result of operation with low water. We cannot emphasize too strongly the
need for the operator to periodically check the low water controls and to follow good maintenance and testing practices.
Cross-connecting piping to low water devices must be internally inspected periodically to guard against any stoppages
which could obstruct the free flow of water to the low water devices. Float bowls of these controls must be inspected
frequently to check for the presence of foreign substances that would impede float ball movement.
The waterside condition of the pressure vessel is extremely important. Waterside surfaces should be inspected frequently
to check for the presence of any mud, sludge, scale or corrosion.
The services of a qualified water treating company or a water consultant to recommend the proper boiler water treating
practices are essential.
The operation of this equipment by the owner and the operating personnel must comply with all requirements or regulations of their 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 proceeding.
i
TABLE OF CONTENTS
Section 1
Introduction
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System features: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Section 2
Components
PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Human Machine Interface (HMI). . . . . . . . . . . . . . . . . . . . . . . . .
Servo Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
3
5
Section 3
Configuration
Configuration Screen #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
"Factory Only" Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Set Points" screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 4
Commissioning
Accessing Commissioning screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Actuator Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Setting actuator stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Burner Light Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Setting Combustion Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
O2 trim and VSD operation with parallel positioning combustion control.4-21
Section 5
Troubleshooting...........5-1
Section 6
Parts..............................6-1
Appendix.......................7-1
ii
Notes
Section 1
HAWK ICS Integral Parallel Positioning
Combustion Control
(Addendum to manual 750-197)
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System features: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Milwaukee, Wisconsin
www.cleaver-brooks.com
Section 1 — HAWK ICS Integral Parallel Positioning Combustion Control
A. INTRODUCTION.
The Parallel Positioning Combustion Control system is based
on the HAWK ICS hardware platform.
With Parallel Positioning Combustion Control combustion
air, fuel (fuels) and the FGR control values are positioned
using individual actuators. This type of control provides
greater flexibility when compared with a single point (jack
shaft) system.
Table 1-1 System Features
Number Of Combustion Curve Break Points
10 minimum, 20 maximum (each fuel) with independent
light off position for each fuel.
Number of fuels
2 (note 1)
FGR Control
Yes
Number of Actuators
Up to 4
Combustion Air Variable Speed Drive
Yes (note 2)
Oxygen Trim Control
Yes (note 3)
The control system has cross limiting function to insure
optimum combustion and safety.
B. SYSTEM FEATURES:
Note: 1 One fuel can be used at the time.
Note: 2 Optional variable speed drive will be required.
Cleaver-Brooks will supply Allen-Bradley VSD. For
other VSD brands please contact Cleaver-Brooks.
Note: 3 Optional stack O2 analyzer will be required.
Gas Actuator
Fuel Oil Actuator
Damper Actuator
Figure 1-1 Air and Fuel Actuators
1-2
Part No. 750-217
Section 2
Components
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Human Machine Interface (HMI). . . . . . . . . . . . . . . . . . . . . . . . . 3
Servo Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Milwaukee, Wisconsin
www.cleaver-brooks.com
Section 2 — Components
A. CONTROLLER
The PLC based modular controller can be easily installed in
the boiler control panel. The PLC is DIN rail mounted.
Figure 2-1 PLC Controller
Rack 1.
1. Processor - L35E
2. DevicenetTM Scanner
3. Power Supply (PA4)
4. Discrete Input Module (16 Ch.)
5. Discrete Output Module (8 Ch.)
6. Analog Input Module (4 Ch.)
7. Analog Output Module (2 Ch.)
8. Thermocouple Input Module (6 Ch.)
9. Discrete Input Module (16 Ch.)
10. Analog Input Module (4 Ch.)
11. Analog Output Module (2 Ch.)
12. Expansion Cable
(Slot 0)
(Slot 1)
(Slot
(Slot
(Slot
(Slot
(Slot
(Slot
(Slot
(Slot
2)
3)
4)
5)
6)
7)
8)
9)
Rack 2.
13. Power Supply (PA2)
14. Solid State Output Module (8 Ch.)
15. Analog Input Module (4 Ch.)
16. Analog Input Module (4 Ch.)
17. Right End Cap Terminator
(Slot 10)
(Slot 11)
(Slot 12)
Please refer to the HAWK ICS Operation and Maintenance
manual (750-197) for PLC component mounting and
removal.
A CompactLogix L35E PLC processor is used for the HAWK
ICS with integral parallel positioning combustion control
option.
Figure 2-2 L35E PLC Processor
2-2
Part No. 750-217
Section 2 — Components
Human Machine Interface (HMI).
The HAWK ICS with integral parallel positioning combustion
control is available only with the 10" touch screen HMI. The
HMI communicates with the PLC using an RS-232 serial
connection. Optional Ethernet HMI is also available.
10 Inch
Screen
Figure 2-3 Human Machine
Interface (HMI)
B. ACTUATORS MOTORS
There are three types of actuators available.
Figure 2-4 3 lb.-ft Actuatorr
Figure 2-5 15 lb.-ft and 37lb.-ft Actuator
Part No. 750-217
2-3
Section 2 — Components
Figures below show typical actuators mounting.
Figure 2-6 Gas Valve with
Actuator
Figure 2-7 Air Damper Actuator
2-4
Part No. 750-217
Section 2 — Components
C. WIRING
Typical wiring of the actuators is shown on figure 2-8
120 AC
85
DO
VAC 1
10:
F6
(2 AMP)
60
DO
VAC 2
10:
FEEDBACK
POWER
SUPPLY
4
(L1) (L2)
(12VDC)
(+)
(-)
62
61
AI
V/I in 011:0
AI
V/I in 111:0
AI
V/I in 311:0
AI
ANLG COM
11:0
OUT 0
10:0
DO
OUT 1
10:1
AIR
ACTUATOR
(S1)
4
2 (DIR1)
93
1 (NEU)
4
G (GND)
DO
OUT 3
10:3
96
(WPR)
6
(S2)
5
GAS
ACTUATOR
DO
OUT 2
10:2
95
7
3 (DIR2)
92
4
95
96
4
3 (DIR2)
2 (DIR1)
1 (NEU)
G (GND)
(S1)
7
(WPR)
6
(S2)
5
RED
WHT
94
AI
V in 0+
11:0
BLK
SHIELDED CABLE
BELDEN 8723
(NOTE 7)
RED
WHT
97
BLK
AI
V in 1+
11:1
SHIELDED CABLE
BELDEN 8723
(NOTE 7)
FGR
ACTUATOR
(S1)
RED
AI
V in 3+
11:3
WHT
115
7
(WPR)
6
(S2)
BLK
5
4
(DIR2) 3
(DIR1)
2
(NEU)
1
(GND)
G
DO
OUT 6
10:6
DO
OUT 7
10:7
113
114
4
Figure 2-8 Typical Actuators Wiring
Part No. 750-217
2-5
Section 2 — Components
Notes:
2-6
Part No. 750-217
Section 3
Configuration
Configuration Screen #1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
"Factory Only" Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Set Points" screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Milwaukee, Wisconsin
www.cleaver-brooks.com
Section 3 — Configuration
A. CONFIGURATION SCREEN #1.
For system configuration please refer to the Section 4 of
HAWK ICS Manual (Part # 750-197). The purpose of this
manual is to show special features that apply to the units
with parallel positioning combustion control only.
Figure 3-1 Configuration Screen #1
Please note that selections for the following options have
been added:
• O2 trim.
• FGR Inlet Temperature (Replaces Oil Temperature
Option)
• FGR
• FGR actuator action on purge
The O2 trim selection automatically activates the O2
analyzer option.
There is also a screen selector push button to access the
"Factory Only" screen.
3-2
Part No. 750-217
Section 3 — Configuration
B. "FACTORY ONLY" SCREEN
The "Factory Only" screen is reserved for the options to be
selected by the factor y personal or a Cleaver-Brooks
authorized representative only prior to the system shipment
or startup. This screen is password protected.
! Warning
This screen should be used
only by an authorized CleaverBrooks factory representative
Figure 3-2 Factory Only Options Screen
On this screen you can enable:
• Variable Speed Drive (VSD) for combustion air fan.
• Parallel positioning combustion control (PLC slot 10
and 11)
• Parallel positioning combustion control (PLC slot 12).
Please note that PLC slot 12 is required for parallel
positioning system in conjuction with VSD.
Part No. 750-217
3-3
Section 3 — Configuration
! Warning
Selecting Drive or Parallel Positioning combustion control will
delete any existing combustion curves.
Figure 3-3 Set Points Screen
C. SET POINTS" SCREEN
There is a selection for FGR low temperature hold. If this
option is selected the FGR valve will be positioned to the
value defined by the "POS %" push button until the flue gas
temperature reaches the value defined by the "SP" push
button.
Note: As a default, flue gas temperature at the boiler outlet
is used as a process variable for this feature. If a
thermocouple on the FGR duct at the burner inlet is installed
and the option for "FGR Inlet Temperature" is selected on
"Config. 1" screen, then this temperature is used as a
process variable.
3-4
Part No. 750-217
Section 4
Commissioning
Accessing Commissioning screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Actuator Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Setting actuator stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Burner Light Off. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Setting Combustion Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
O2 trim and VSD operation with parallel positioning combustion control.4-21
Milwaukee, Wisconsin
www.cleaver-brooks.com
Section 4 — Commissioning
A. ACCESSING COMMISSIONING SCREEN
From the Screen Select Menu choose "Start Up".
The following screen will appear
Figure 4-1 Warning Screen
Read the warning message and acknowledge it by pressing
"I"VE READ THE WARNING, I AM QUALIFIED" button.
Enter a password "5463".
The following screen will appear.
.
4-2
Part No. 750-217
Section 4 — Commissioning
Figure 4-2 Warning Screen
Press "Combustion Set Up" button.
Part No. 750-217
4-3
Section 4 — Commissioning
Figure 4-3 Warning Screen
Press the "Confirm Combustion Set Up" push button to
choose actuators' selection screen.
4-4
Part No. 750-217
Section 4 — Commissioning
Figure 4-4 Actuators Selection Screen
Note: If the FGR option is not selected, the FGR actuator will
not be displayed.
In order to proceed with the combustion set up, the
actuators must be commissioned.
Note: For a single fuel unit or if a second fuel is not used at
this time, the second fuel actuator can be left
unconfigured (color red).
B. ACTUATOR CONFIGURATION
The 90° rotation is set at the factory, but has to be verified,
using the following instructions.
The wiring has been set-up such that the direction for open
travel is counter-clockwise as viewed from the potentiometer
Part No. 750-217
4-5
Section 4 — Commissioning
end. If this rotation is not correct, you can swap the wires
on 2 & 3 and 5 & 7 to change the direction of travel.
C. SETTING ACTUATOR STROKE
Actuators travel has been factory pre-set to 90° rotation. It
is recommended not to change the end switches setting. For
a detail procedure on how to stroke the actuator, please
refer to the Appendix of this manual.
Make sure that all output shafts couplings and setscrews are
loose and that the valves can be rotated freely.
Press the "Commission Actuator" push button. Using the
"Actuator Close" pushbutton move the actuator to the full
close position. Close the damper (valve) and tighten
couplings and set screws.
Drive the actuator to the mechanical open limits of the
damper (valve). Back the actuator off a little (0.05-0.1V) and
press the "Confirm Maximum Position" push button. The
stored maximum position will be displayed.
Table 4-1 Actuator Commissioning Screen (Confirm Maximum Position)
Drive the actuator to the mechanical close limit of the
damper (valve). After the actuator reaches the mechanical
stop, drive the actuator up a little (0.05-0.1V) and press the
4-6
Part No. 750-217
Section 4 — Commissioning
"Confirm Minimum Position" push button. The stored
minimum position will be displayed.
Figure 4-5 Actuator Commissioning Screen (Confirm Minimum Position)
Note: The recommended reading for minimum position is
from 4.2 to 4.5 VDC. The recommended reading for the
maximum position is from 7.2 to 7.5 VDC.
• Valid values for minimum position are as follows:
Greater then 1 VDC, but at least 1VDC lower then the
maximum position.
• Valid values for maximum position are as follows:
Less then 9 VDC, but at least 1VDC greater then the
minimum position.
Press "Actuator Commissioning Complete" push button.
The display on the actuators' overview will change to
"Actuator Commissioned".
Repeat actuator-commissioning steps for each actuator.
Part No. 750-217
4-7
Section 4 — Commissioning
Figure 4-6 Actuators Selection Screen (Actuators Configured)
Press "Set Up Complete" push button.
Note: If "Set Up Complete" push button is not present, make
sure that the fuel selector switch is in proper position
(Gas or Oil).
4-8
Part No. 750-217
Section 4 — Commissioning
D. BURNER LIGHT OFF.
Note: It is recommended to temporarily replace the flame safe
guard modbus communication card with a regular
CB780 display. Ignore "Modbus Communication Error"
alarm.
! Important
Yo u c a n t o g g l e b e t w e e n
"Combustion Set Up" and
" B u r n e r C o n t r o l " s c re e n
without shutting the burner
off. Accessing this screen via
"Screen Select Menu" screen
will require a password and
burner shutdown.
Figure 4-7 Combustion Set Up Screen
It is recommended for new start-up to begin with a new
combustion curve profile.
Press "New Profile" and select "Yes".
Part No. 750-217
4-9
Section 4 — Commissioning
Figure 4-8 Confirm New Profile Screen
Note that "Store Purge Position" and "Store Light Off
Position" push buttons are blinking. It means that these
values have not been set.
Open air actuator to the desired purge position and press
"Store Purge Position" push button (purge position value
can be readjusted later if necessary). Minimum limit for
purge position is 50%. After purge position is set, value of
purge position will be displayed and air actuator will drive
close.
! Important
Make sure that the air actuator is stopped at the desired
purge position prior to pressing the “Save Purge Position”
push button.
4-10
Part No. 750-217
Section 4 — Commissioning
Figure 4-9 Combustion Set Up Screen (Purge Set)
Slightly open the air and fuel actuators and press the "Store
Light Off Position" push button (light off position values can
be readjusted later if necessary). The maximum limit for the
light off position is 25% (air and fuel). After the light off
position is set, the values of light off position will be
displayed.
Part No. 750-217
4-11
Section 4 — Commissioning
Figure 4-10 Combustion Set Up Screen (Light Off Set)
Make sure that the natural gas manual shutoff valve is
closed. Turn the burner switch "On".
4-12
Part No. 750-217
Section 4 — Commissioning
Figure 4-11 Combustion Set Up Screen (Burner Start Pushbutton)
The "Burner Start" pushbutton has to be blinking at the left
bottom corner of the screen (if not, check the operating
limits inputs 2/5 and 2/6). Press the "Burner Start" push
button (see Figure 4-11). The combustion air blower shall
start and the air damper will drive to the open position.
Once purge is complete, the air damper will move to the
close (light off) position.
When the air damper is closed, the "Light Off" push button
will start blinking at the bottom left corner(see Figure 4-12).
Part No. 750-217
4-13
Section 4 — Commissioning
Figure 4-12 Combustion Set Up Screen (Light Off Pushbutton)
Place flame relay in the "Test" mode and press "Light Off"
pushbutton. Burner pilot shall come on. If air and fuel
position has to be adjusted, shut the burner down and make
the necessary adjustments and press “Store Light Off
Position” push button. Adjust air and fuel positions, if
necessary, store light off position again. Stop and start
burner several times to make sure that pilot is stable.
Open manual gas shut off valve and place flame relay in the
"Run" mode. Main flame shall come on.
Adjust flame by changing positions of the air and gas
actuators. Once flame is adjusted, press "Store Light Off
Position" push button.
Turn the burner "Off" and start it again. Make sure that
burner lights off successfully.
E. SETTING COMBUSTION CURVE.
Start the burner. Once burner is started and main flame is
established, screen should looks like the one shown on
Figure 4-13.
4-14
Part No. 750-217
Section 4 — Commissioning
Figure 4-13 Combustion Set Up Screen (Minimum Point)
Please note that point #1 with "Min" indicator to the left is
highlighted.
Note: The highlighted point is the active point to be adjusted.
Adjust the minimum position point by adjusting the air, fuel
and FGR (if applicable) actuator positions to achieve good
combustion.
When you are satisfied with the combustion reading press
the "Store" push button.
Part No. 750-217
! Important
A l way s u s e c a l i b ra t e d
portable flue gas analyzer
to adjust combustion!!
4-15
Section 4 — Commissioning
Figure 4-14 Combustion Set Up Screen (Minimum Point Set)
Note that the numbers on the highlighted Min row have
changed. The text on the bottom row of the table will change
(for the short period) from "Data Point has not been stored"
to "Data Point has been stored" and once the “Store”
button is released, number 2 row will be highlighted.
Note: If O2 trim or FGR are not used, the numbers in those
columns will be left at 0.
Adjust combustion similar to the previous point and press
the "Store" pushbutton.
If the point to be set is not within acceptable limits, the
bottom row will display "Error, out of range message" and
the point will not be stored.
4-16
Part No. 750-217
Section 4 — Commissioning
Figure 4-15 Combustion Set Up Screen (Error Value Out Of Range)
Conditions for the point to be valid are; air and fuel position
values for the point to be set must be greater then a previous
point and less then next point (if the next point has been
set).
You can also skip a point. The values for skipped point are
calculated as an average between the previous and the next
point.
Note: Only one point can be skipped at the time. If more then
one point is skipped, "Store" pushbutton will disappear.
Once the # 10 point is set, you should see the "Set Up
Complete" pushbutton on a bottom row of the screen. This
means that the minimum requirements for the combustion
profile curve have been met.
Part No. 750-217
4-17
Section 4 — Commissioning
Figure 4-16 Combustion Set Up Screen (#10 Point is Set)
If the burner is at the maximum firing rate, the combustion
profile setting can be finished at this time.
If the burner is not at the maximum firing, continue setting
points. A maximum of 20 points can be set.
Once the maximum firing rate is set, it is recommended to
confirm the combustion set up by moving from point to point
using "Prv Point" pushbutton. Once the previous point is
highlighted, the actuator will move to the position set for this
point. If adjustments have to be made to the point, do it by
using the "Actuator Open" and "Actuator Close"
pushbuttons and then confirm the setting by pressing
"Store" pushbuttons.
When you are satisfied with the combustion curve profile,
press "Set Up Complete" pushbutton.
4-18
Part No. 750-217
Section 4 — Commissioning
Figure 4-17 Confirm Set Up Message
Confirm profile by selecting "Yes".
The screen will change to the combustion control display.
Part No. 750-217
4-19
Section 4 — Commissioning
Figure 4-18 Combustion Control Screen.
There are three sets of barographs, indicating set points
(SP) and actual positions of the actuators (PV). These
values are in % of travel.
There is feedback signal indication for each actuator in VDC.
Note that the minimum and maximum values that were set
during the actuators' commissioning are also displayed.
Steam pressure and set point are displayed.
If the unit is supplied with an O2 analyzer and trim, the
actual O2 and O2 trim set points are displayed.
Firing rate mode can be changed using "Man", Auto" or
"Rem/Llag" push buttons. When the firing rate control is in
"Manual" mode, the firing rate can be changed using
"Close" and "Open" pushbuttons.
The firing rate control response to the load changes can be
adjusted using the "Pgain" (Proportional Gain), "Igain"
(Integral Gain) and "Dgain" (Derivative Gain) pushbuttons.
Increasing proportional and integral gain values will make
the control respond faster to the load changes and vice
versa. Derivative gain normally is kept to 0.
4-20
Part No. 750-217
Section 4 — Commissioning
F. O2 TRIM AND VSD OPERATION WITH PARALLEL POSITIONING
COMBUSTION CONTROL.
The purpose of this section is to outline the specifics of the
O2 trim and VSD options as they are applied to the parallel
positioning combustion control.
For more information on O2 trim and VSD please refer to the
manuals (Part No. 750-198 and 750-210).
Figure 4-19 Blower VSD Screen.
Combustion air blower speed is based on the firing rate.
The following equation is used to calculate PLC output to the
variable speed drive.
Output%=((HL-LL)/100*Fir Rate+LL)*60/66
Where: Output = PLC output (Module 9 output 0) expressed
in %. 0% = 4 ma, 100% = 20 ma.
HL = VSD high limit in % (Factory default =100%) Allowable
range is from LL to 100%.
LL = VSD low limit in %. (Factory default = 70%) Allowable
range is from 50% to HL.
Fir Rate = Firing rate output %.
60 = line frequency in Hz.
66 = Maximum drive frequency output in Hz.
Part No. 750-217
4-21
Section 4 — Commissioning
When O2 trim is used, the correction is applied to the air
actuator position on the units without VSD and to VSD speed
on the units with VSD.
Figure 4-20 O2 Trim Screen.
The correction is a multiplier, based on the O2 trim
controller output and trim correction factor.
If trim correction factor is 20% (factor y default and
maximum value), the maximum correction to the air position
or VSD speed is +/- 10%. If O2 trim control output is 0%
then 0.9 will be multiplies to the VSD Output, calculated
using previous equation. If O2 trim control output is 100%
then 1.1 will will be multiplies to the VSD Output, calculated
using previous equation.
“O2 Trim Not Set” indicator: This message is displayed if the
O2 trim control is placed in “Auto”, but the O2 trim has not
been set for the fuel selected. If this message is displayed,
the O2 trim control output is set to 50% (between the
maximum and minimum limits).
4-22
Part No. 750-217
Section 5
Troubleshooting
Milwaukee, Wisconsin
www.cleaver-brooks.com
Section 5 — Troubleshooting
A. TROUBLESHOOTING.
This section applies only to the troubleshooting, related to
the parallel positioning combustion control commissioning
and operation. For troubleshooting related to the HAWK ICS
components and general operation, please refer to the HAWK
ICS Operation and Maintenance Manual (Part # 750-197).
Table 5-1 Parallel Positioning Commissioning.
Problem
Possible Cause
Corrective Action
"Start Up" screen selector push button is
not present on Screen Select Menu
Parallel positioning control is not
selected.
From "Factory Only" configuration screen. Select
"Par. Pos. (Slot 10,11)" and (if applicable) "Par. Pos.
(Slot 12)"
FGR actuator is not present on the
"Actuator Selection" screen.
FGR option is not selected.
From "Config 1" screen. Select FGR.
Actuator does not move during
commissioning of the actuator.
Wiring
Check for neutral wire on terminal (1) of the
actuator.
Check power on terminals VAC1 and VAC2 of the slot
10. Should be 120 VAC. If power is not present,
check wiring.
Actuator rotation wrong
Wiring
Switch wires between terminals (2) and (3) on the
actuator.
Feedback voltage decreases when actuator
is opening.
Feedback wiring
Switch wires between terminals (5) and (7) on the
actuator.
Maximum or minimum position of the
actuator is not accepted during actuator
commissioning.
Feedback signal is not within the
limits.
Make sure that maximum and minimum positions
are within acceptable limits.
Minimum feedback signal is greater then 1 VDC, but
at least 1 VDC less then maximum feedback.
Maximum feedback signal is less then 9 VDC, but at
least 1 VDC greater then minimum feedback.
With actuators configured, "Set Up
Complete" pushbutton is not present on the
"Actuators Selection" screen.
Fuel selector switch is not in proper
position.
Check for input 10 (Gas) or 11 (Oil) on the slot 2.
"Light Off Not Set" and "Purge Not Set" are
blinking, but fuel and air actuators cannot
be moved.
Burner switch is "On"
Turn the burner switch "Off"
"Burner Start" pushbutton is not present on
the "Combustion Set Up" screen.
Operating limits are not complete.
Following conditions must be met:
Burner control alarm (Input 2:12) Off
Operating Limits (Input 2:5) On
External Limits (Input 2:6) On
Load Demand On
5-2
Part No. 750-217
Section 5 — Troubleshooting
Table 5-1 Parallel Positioning Commissioning.
Blower starts and air actuator moves to the
open position. Then burner shuts down
with high fire switch not proven.
Air actuator is not in proper position
for purge.
Wiring
Make sure that air actuator's feedback position is
within 5.0% of what purge position is set for.
Output 13 on slot 12 should be "On" when air
actuator is in purge position. If output is "On" check
if high fire relay is energized. Make sure that VAC1
and VAC2 terminal on slot 10 are "hot" (120 VAC).
Check if air damper binds.
If all above fails, re-commission air actuator.
Air actuator comes back to the minimum
position, but "Light Off" pushbutton does
not appear.
Air and fuel actuators are not in
proper positions.
Air and fuel actuators feedback position must be at
least within 5.0% of the set light off position.
Check for operating limits (Input 2:5 shall be On)
"Light Off" pushbutton does not disappear
when pressed and pilot does not come on.
Wiring
Check for low fire relay output (Output 12 slot10).
Low fire relay should be energized. Make sure that
VAC1 and VAC2 terminal on slot 10 are "hot" (120
VAC).
Burner lights, but "Store" pushbutton is not
present
Wiring
Inputs 2 and 7 on the module 2 must be "On".
"Store" pushbutton disappeared.
Set up sequence
No more then one point can be skipped without
storing.
Burner has O2 trim control, but all points
for O2 on the set up table are filled with
zeros.
O2 trim option is not selected.
Select O2 trim option from "Config. 1" screen.
“Error Value Out of Range” is displayed
when trying to set combustion curve point
1. Air and fuel position values shall
be greater than the previous point
and lower than the next point.
2.O2 value is lower than 1% or the
O2 trim option is selected by
mistake.
1. Readjust combustion curve point
Part No. 750-217
2. Make adjustments to correct O2 value or de-select
O2 trim if it is wrongly selected.
5-3
Section 5 — Troubleshooting
Table 5-2 Parallel Positioning Control Operation
With the burner switch "On", message
comes up "Fuel Commission Is Not
Complete" and burner does not start.
Fuel is not commissioned.
Go through commissioning procedure.
Blower starts and air actuator moves to the
open position. Then burner shuts down
with high fire switch not proven.
Air actuator is not in proper position
for purge.
Wiring
Make sure that air actuator's feedback position is
within 5.0% of what purge position is set for.
Output 13 on slot 12 should be "On" when air
actuator is in purge position. If output is "On" check
if high fire relay is energized. Make sure that VAC1
and VAC2 terminal on slot 10 are "hot" (120 VAC).
Check if air damper binds.
If all above fails, re-commission air actuator.
Pilot does not energize and flame
safeguard displays alarm indicating low
fire switch not proven.
Air and fuel actuators are not in
proper positions.
Wiring
Air and fuel actuators feedback position must be at
least within 5.0% of the set light off position.
Check for operating limits (Input 2:5 shall be On)
Check for low fire relay output (Output 12 slot10).
Low fire relay should be energized. Make sure that
VAC1 and VAC2 terminal on slot 10 are "hot" (120
VAC).
Burner shuts down with "Actuator Out Of
Position" alarm message
Bad actuator.
Check feedback voltage. If not within limits of
actuator's configuration, replace actuator,
commission it and set combustion.
5-4
Part No. 750-217
Section 6
Parts
Milwaukee, Wisconsin
www.cleaver-brooks.com
Section 6 — Parts
Table 6-1 Programmable Controller
Description
Processor (L35E)*
Power Supply (PA4)
Discrete Input Module 16 Ch. 120 VAC
Discrete Output Module, Isolated, 8 Ch. 120 VAC
Analog Input Module, 4 Ch.
Analog Output Module, 2 Ch.
Device Net Scanner*
Termination cap
Thermocouple module, 6 Ch.
Power Supply (PA2)
Expansion cable
Solid State Output Card, 16 Ch.
Part No.
833-2959
833-2960
833-2842
833-2872
833-2835
833-2844
833-2845
833-2838
833-2837
833-2834
826-126
833-3050
*Requires programming
Table 6-2 Actuators
Description
Actuator 3 in-lb torque
Actuator 15 in-lb torque
6-2
Part No.
945-225
945-226
Part No. 750-217
Appendix
Stroke the actuator.
Remove fuse for the feedback power supply. Remove the
three feedback wires from the feedback potentiometer
terminals 5,6, & 7.
! Warning
In the case of an actuator which has the cover removed and
is ready to operate there is the risk that live parts may be
touched and thus a shock received. Terminals 2 & 3 have
120 vac power applied to them!
Place a voltmeter between terminals 5-6 on the actuator. Set
the meter to read ohms.
The actuator needs to be configured such that at low fire
position the resistance will read 1666 ohms +/- 50 ohms.
Press "Commission Actuator" push button.
Milwaukee, Wisconsin
www.cleaver-brooks.com
Figure 7-1
Appendix —
Figure 7-2 Actuator Commissioning Screen
Use the Hawk ICS actuator commissioning screen to drive
the actuator to the closed position. If the actuator will not
close far enough to read the desired ohms rotate Cam switch
(the one furthest from the potentiometer) counter clock wise
(looking from the potentiometer side) with the white knurled
adjuster so that actuator will continue to turn.
Adjust switch until meter reads 1666 ohms +/- 50 ohms.
You may need to use the commissioning screen OPEN and
CLOSE button to verify the setting.
Figure 7-3 Adjust Switch
7-2
Part No. 750-217
Appendix —
Connections
1 = Neutral
2 = Direction 1
3 = Direction 2
4 = Not us ed
5 = + (S 2)
6 = Wiper
7 = (S 1)
Components
R 1 = Potentiometer
S 1 = Limit microswitch
S 2 = Limit microswitch
F 1, F 2 = Potentiometer s ecurity s crews
4
3
2
1
S2
S1
5
6
7
R1
Figure 7-4 Actuator Stop Adjustments
After the closed position has been set, use the
commissioning screen OPEN button to set the cam switch
closest to the potentiometer until the open position reading
on the ohm meter is 3333 ohms +/- 50 ohms.
Verify both positions by running the actuator between the
closed and open positions and monitoring the ohm meter.
Remove the ohm meter and reattach the feedback wires onto
terminals 5,6,& 7.
Press "Return to Previous Screen" push button and
continue with the next actuator.
When all the actuators are stroked, replace the fuse for the
feedback power supply. The feedback voltage on the Hawk
ICS screen should read approximately 4.4 volts at the closed
position and 7.5 volts at the open position.
Part No. 750-217
7-3
7-4
Slot 9 Analog Outputs
O9/0 O2 trim/VSD
O9/1
Slot 8 Analog Inputs
I8/0 Analog 0
I8/1 Analog 1
I8/2 Analog 2
I8/3 Analog 3
Recycle limit
Exter. Start Intlk
Non-Recycle Lmt
Drive to LF FARC
Start slave Blr
Load Demand
Alarm Output
Boiler ready
Slot 3 Digital Outputs
O3/0
O3/1
O2/2
O3/3
O3/4
O3/
O3/6
O3/7
I2/0
I2/1
I2/2
I2/3
I2/4
I2/5
I2/6
I2/7
I2/8
I2/9
I2/10
I2/11
I2/12
I2/13
I2/14
I2/15
Blower On
Purge
Release to mod.
Low Hire
High Fire
Ready to start
External Interlk.
ALFCO
Pilot
Main Fuel
Fuel 1 Selection
Fuel 2 Selection
FSG Alarm
LWCO shutdown
Rem or LL Avail
Burner Switch
Slot 2 Digital Inputs
Steam Boilers
Control Out
Control Out (L-L)
Slot 5 Analog Outputs
O5/0
O4/1
O10/0
O10/1
O10/2
O10/3
O10/4
O10/5
O10/6
O10/7
O10/8
O10/9
O10/10
O10/11
O10/12
O10/13
fire
Prove Low fire
Prove High
Air Act. Open
Air Act. Close
NG Act.Open
NG Act.Close
Oil Act.Open
Oil Act.Close
FGR Act.Open
FGR Act.Close
I11/0
I11/1
I11/2
I11/3
Air Act. Feedback
Gas Act feedback
Oil Act. Feedback
FGR Act feedback
Slot 10 Sol. State Out Slot 11 Analog Inputs
Steam Pressure
Water Level
O2
Remote Mod
Slot 4 Analog Inputs
I4/0
I4/1
I4/2
I4/3
I12/0
I12/1
I12/2
I12/3
VSD Frequency
Slot 12 Analog Inputs
Stack Temp. (b4 Ec)
Comb. Air
Shell Temp.
FW Temperature
Stack Temp
FGR Temp
Slot 6 Thermocouple In
I6/0
I6/1
I6/2
I6/3
I6/4
I6/5
I7/0
I7/1
I7/2
I7/3
I7/4
I7/5
I7/6
I7/7
I7/8
I7/9
I7/10
I7/11
I7/12
I7/13
I7/14
I7/15
HLC
ALWCO
LGP/LOT
HGP/HOT
Low Oil Pressure
High Oil Press.
Oil Drawer Sw.
Atomi Air Press
Comb. Air Press.
High Water
Auxiliary #1
Auxiliary #2
Auxiliary #3
Fuel 3 Selection
O2 Status
Slot 7 Digital Inputs
Appendix —
Part No. 750-217
Part No. 750-217
Slot 9 Analog Outputs
O9/0 O2 trim/VSD
O9/1
I8/0
I8/1
I8/2
I8/3
Analog 0
Analog 1
Analog 2
Analog 3
Slot 8 Analog Inputs
Recycle limit
Exter. Start Intlk
Non-Recycle Lmt
Drive to LF FARC
Start slave Blr
Load Demand
Alarm Output
Boiler ready
Slot 3 Digital Outputs
O3/0
O3/1
O2/2
O3/3
O3/4
O3/
O3/6
O3/7
I2/0
I2/1
I2/2
I2/3
I2/4
I2/5
I2/6
I2/7
I2/8
I2/9
I2/10
I2/11
I2/12
I2/13
I2/14
I2/15
Blower On
Purge
Release to mod.
Low Hire
High Fire
Ready to start
External Interlk.
ALFCO
Pilot
Main Fuel
Fuel 1 Selection
Fuel 2 Selection
FSG Alarm
LWCO shutdown
Rem or LL Avail
Burner Switch
Slot 2 Digital Inputs
Hot Water Boilers
Control Out
Control Out (L-L)
Slot 5 Analog Outputs
O5/0
O4/1
O10/0
O10/1
O10/2
O10/3
O10/4
O10/5
O10/6
O10/7
O10/8
O10/9
O10/10
O10/11
O10/12
O10/13
fire
Prove Low fire
Prove High
Air Act. Open
Air Act. Close
NG Act.Open
NG Act.Close
Oil Act.Open
Oil Act.Close
FGR Act.Open
FGR Act.Close
I11/0
I11/1
I11/2
I11/3
Air Act. Feedback
Gas Act Feedback
Oil Act. Feedback
FGR Act Feedback
Slot 10 Sol. State Out Slot 11 Analog Inputs
O2
Remote Mod
Steam Pressure
Slot 4 Analog Inputs
I4/0
I4/1
I4/2
I4/3
I12/0
I12/1
I12/2
I12/3
VSD Frequency
Slot 12 Analog Inputs
Rtrn Temp
FGR Temp
Stack Temp. (b4 Ec)
Comb. Air
Shell Temp.
Slot 6 Thermocouple In
I6/0
I6/1
I6/2
I6/3
I6/4
I6/5
I7/0
I7/1
I7/2
I7/3
I7/4
I7/5
I7/6
I7/7
I7/8
I7/9
I7/10
I7/11
I7/12
I7/13
I7/14
I7/15
HLC
ALWCO
LGP/LOT
HGP/HOT
Low Oil Pressure
High Oil Press.
Oil Drawer Sw.
Atomi Air Press
Comb. Air Press.
Low Flow
Auxiliary #1
Auxiliary #2
Auxiliary #3
Fuel 3 Selection
O2 Status
Slot 7 Digital Inputs
Appendix —
7-5
Appendix —
Notes
7-6
Part No. 750-217
NOTES
e-mail: [email protected]
Web Address: http://www.cleaver-brooks.com

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