Melink INTELLI-HOOD-2

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Summary

Keypad Displays and Audible Sounds

Typical Display

Shows the standard indicator layout and status lights on the keypad.

Normal Operation

Describes the expected behavior and visual feedback during normal system use.

Indicator Light Status

Explains the meaning of clean and fault light indicators, including color states.

Audible Feedback

Outlines the beep patterns and their implications for system feedback and alerts.

System Troubleshooting and Repair Actions

Fans Not Running

Addresses issues where the keypad is normal but fans fail to operate.

Keypad Unresponsive, Fans Not Starting

Covers scenarios where the keypad is dead and fans do not activate.

Emergency Bypass Mode Display (-E)

Explains the '-E' display and how to exit emergency bypass mode.

Fans Shut Off Periodically

Diagnoses fans that stop running at regular 10-minute intervals.

Keypad Blank, Fans Running

Troubleshoots a blank keypad when the fans are operational.

Keypad Blank, Fans Not Running

Covers cases where the keypad is blank and fans are not operating.

Low Temperature Fault (F2-h)

Details troubleshooting for low temperature sensor readings indicated by F2-h.

High Temperature Fault (F2-H)

Guides on resolving high temperature sensor readings indicated by F2-H.

VFD Fault (F3-U)

Provides steps for diagnosing and resolving VFD faults indicated by F3-U.

Low Optic Fault (F1-o, F3-o)

Explains how to fix low optic sensor faults shown as F1-o or F3-o.

High Optic Fault (F3-9)

Addresses troubleshooting for high optic sensor faults indicated by F3-9.

Auxiliary Temperature Fault (F5-h, F6-h)

Covers faults related to auxiliary temperature sensors F5-h or F6-h.

Phone Fault (F-PH)

Details troubleshooting steps for phone line connection faults (F-PH).

System Disabled Display (d-on)

Explains the 'd-on' display and how to resolve system disablements.

Flashing Bar Graph, Keypad Wont Shut Off Fans

Troubleshoots a flashing bar graph where fans cannot be turned off.

Red Text Display, No Bar Graph

Diagnoses issues with red text display and non-functional bar graphs.

VFDs Cycling On;Off

Addresses VFDs that repeatedly turn on and off during normal operation.

Constant Tone Noise, Full Speed Fans

Explains a constant tone noise with fans running at full speed.

Heartbeat Beeping Noise

Guides on troubleshooting a rhythmic 'heartbeat' beeping from the keypad.

Fans Speeding Up, Not Slowing Down

Resolves issues where fans increase speed but do not slow down.

VFD Troubleshooting

Resetting and Restarting VFDs

Procedure for clearing VFD faults and restarting the variable frequency drives.

VFD Not Accelerating to Full Speed

Diagnoses why a VFD fails to reach its maximum operational speed.

VFD Power Loss Fault (F3)

Troubleshooting steps for the VFD Power Loss fault (F3).

VFD Overvoltage Fault (F5)

Guides on resolving VFD Overvoltage faults indicated by F5.

VFD Motor Overload Fault (F7)

Details troubleshooting for VFD Motor Overload faults (F7).

VFD Hardware Overcurrent Fault (F12)

Addresses VFD Hardware Overcurrent faults indicated by F12.

VFD Ground Fault (F13)

Provides steps for diagnosing and resolving VFD Ground Faults (F13).

VFD Auto Restart Fault (F33)

Explains how to troubleshoot VFD Auto Restart Faults (F33).

F100 Fault on Powerflex 400 VFDs

Resolves the F100 fault specifically on Powerflex 400 VFD models.

The Melink Intelli-Hood-2 Controls system is designed to manage and optimize commercial kitchen ventilation systems, providing energy solutions for a brighter tomorrow. This document outlines the keypad displays, audible sounds, and comprehensive troubleshooting steps for common issues encountered with the system, including VFD (Variable Frequency Drive) faults.

Function Description

The Melink Intelli-Hood-2 Controls system primarily regulates kitchen exhaust and supply fans based on cooking activity, optimizing energy consumption. In normal operation, the keypad cycles through up to four hoods (H-1, H-2, etc.), displaying a bar graph that indicates the fan speed for each channel. The system uses various sensors, including optic and temperature sensors, to detect cooking activity and adjust fan speeds accordingly. It can also integrate with other building systems, such as fire suppression and building automation systems, for comprehensive control.

Keypad Displays and Audible Sounds:

Normal Operation: The keypad cycles through hood channels (H-1, H-2, etc.) and displays a bar graph indicating the fan speed for each channel.
Clean Light:
- Blank: Indicates normal operation with no optics faults.
- Flashing Red and Green: Signals an Optics Fault.
Fault Light:
- Blank: Indicates normal operation with no faults.
- Green: Indicates the system is receiving a digital input on terminals 25 through 33, which is a normal occurrence on many systems.
- Red: Indicates any system fault. Fault codes are detailed in the troubleshooting section.
Sounds:
- Silent: Typically, the keypad is silent during normal operation.
- Beep: Occurs when buttons are pressed (e.g., turning on/off fans or lights) or when an external input commands the system to turn on via the Remote On/Off function. Beeping can also indicate other problems, as detailed in the troubleshooting section.
- Constant Tone Noise: Indicates an optic block function where the Optic Receiver sees zero light from the Emitter for 15 minutes. Fans will run at full speed. Pressing any button will display an optic fault, and fans will no longer be locked at full speed, running as temperature-only.
- "Heartbeat" Beeping Noise (continuous short beeps every second): Indicates a 24V short in the hood sensor circuit, causing the current limiting device to cycle processor board power and reboot the processor.

Important Technical Specifications:

Hood Channels: Supports up to 4 hoods (H-1, H-2, H-3, H-4).
Digital Inputs: Utilizes digital input terminals 25 through 33 for various system signals.
Temperature Sensors: The system uses temperature sensors for monitoring, with specific channels for supply temperature (channel 5) and kitchen space temperature (channel 6).
Optic Sensors: Employs optic sensors to detect cooking activity.
VFD Integration: Designed to work with Variable Frequency Drives, specifically Allen Bradley Powerflex 4 VFDs, to control fan speeds.
Power: The main processor requires 120VAC power.
Emergency Bypass Timer: Default timer length is 10 minutes.
Clock Battery Backup: The autocal board includes a battery backup for the system clock (SY-12).

Usage Features:

Fan Control: Users can turn fans on/off using the "Fans" button.
Light Control: Users can turn lights on/off via the keypad.
Emergency Bypass Mode: Activated when the keypad displays "-E" (e.g., "H2-E"). Users can exit this mode by pressing the "100%" button and then use the "Fans" button to return to normal mode.
Remote On/Off Function: The system can be commanded to turn on/off by an external input, such as a toggle switch, water wash panel, or Building Automation System (BAS).
Programming Parameters: The system allows for extensive programming through various parameters (e.g., Hx-06 for sensor programming, SY-25 for disabling the Fans button, SY-04/SY-05/Hx-11 for Remote Enable, SY-07 for economizer mode, Hx-10 for short cycle ratio, SY-34 for phone fault, SY-12 for clock programming, Hx04 for hood parameters, Hx08/Hx09 for primary/secondary VFDs, Hx19/Sy32 for VFD type).
VFD Control: The system manages VFDs, including monitoring their status, addressing faults, and adjusting parameters like maximum speed (P035), deceleration time (P040), stop mode (P037), minimum speed (P034), S-Curve (A083), and Start Boost (A084).

Maintenance Features:

Troubleshooting Guides: The manual provides detailed troubleshooting steps for various issues, including:
- Fans not running despite a normal keypad display.
- Keypad unresponsive when the "Fans" button is pressed.
- Keypad displaying "-E" (Emergency Bypass Mode).
- Fans shutting off every 10 minutes.
- Blank keypad with fans running (fire mode).
- Blank keypad with fans not running.
- Low temperature fault (F2-h).
- High temperature fault (F2-H).
- VFD Faults (e.g., F3-U, F4-U).
- Low optic fault (F1-o, F3-o).
- High optic fault (F3-9).
- Auxiliary temperature channel faults (F5-h, F6-h).
- Phone fault (F-PH).
- "d-on" display when the fan button is pressed (system disabled).
- Flashing vertical bar graph and keypad not shutting off fans (exhaust temp alarm mode).
- Red text display scrolling through hoods but no bar graph (VFD programming issue).
- VFDs cycling on and off.
- Constant tone noise (optic block).
- "Heartbeat" beeping noise (24V short in hood sensor circuit).
- Fans increasing speed when optics are blocked but not slowing down (clock programming issue).
VFD Troubleshooting: Specific guidance for Allen Bradley Powerflex 4 VFDs, including:
- Resetting and restarting VFDs.
- Addressing VFDs not accelerating to full speed (checking P031, P032).
- Diagnosing F3: Power Loss (checking AC line, wiring, circuit breaker).
- Diagnosing F5: Overvoltage (checking AC line, motor failure, deceleration time, stop mode, input power, output filter, brake resistor, disconnect switch).
- Diagnosing F7: Motor Overload (checking P033, fan rotation, pulley adjustment, maximum speed, S-Curve, Start Boost).
- Diagnosing F12: Hardware Overcurrent (checking programming, excess load, DC boost, DC brake volts, output side short, motor failure, disconnect switch, VFD HP, current limit).
- Diagnosing F13: Ground Fault (checking motor, external wiring, disconnect switch, VFD defect).
- Diagnosing F33: Auto Restart Fault (checking fault history parameters d007, d008, d009).
- Addressing F100 Fault on Powerflex 400 VFDs (resetting internal timer via A195).
Sensor Maintenance: Instructions for cleaning optic lenses and checking sensor connections.
Cable Inspection: Recommendations to inspect and replace damaged cables or sensors.
Programming Checks: Regular verification of programming parameters to ensure correct system operation.
Component Checks: Guidance on checking VFDs for actual faults, verifying VFD enable jumpers, and inspecting components like sensor cables, Temperature-Y's, APU Header Boards, and Optic Cables.