INTELLI-HOOD TROUBLESHOOTING GUIDE

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INTELLI-HOOD TROUBLESHOOTING GUIDE Melink Corporation(513) 965-7300www.melinkcorp.com

Last Updated 7/22/2015Table of ContentsPageI.About this Document2II.Related Documents2III.Glossary of Abbreviations3IV.Diagnostics/Troubleshooting4a. Touchpad Display4b. System Controller6c. Hood Controller7d. Optic/Temp Sensor7e. VFD’s8f. EF’s9g. MUA Interlock9h. BAS/BACnet10i. AIO10j. ALC11k. APD111

Intelli-Hood Troubleshooting GuideI.About this DocumentThe purpose of this document is to provide basic troubleshooting techniques for the Intelli-HoodKitchen Control System. The intended audience of this document is the end user of the system:the building owner, kitchen manager, kitchen staff, or maintenance technician.II.Related DocumentsOperations and Maintenance Manual Provides information regarding basic operation & maintenance.Installation Manual Provides detailed installation instructions of the components including mechanical installationof parts, power wiring, and control wiring.VFD Manuals Refer to documents provided by the VFD manufacturer for information regarding any aspect ofthe Variable Frequency Drives including power wiring, control wiring, programming, and faults.Information can be found on their respective web pages.System is continually expanding capabilities. Presently, capable of utilizing Modbus control forABB, Allen-Bradley, Trane, Danfoss, Siemens, Schneider, Samsung, & Yaskawa.2

III.Glossary of AbbreviationsThe following terms and abbreviations are used throughout literature pertaining to theIntelli-Hood System. IH: VFD: TP: APU: Air Purge Unit SC:System Controller HC:Hood Controller AT: AIO: Auxiliary Analog Out Device ALC: Auxiliary Light Controller APD: Auxiliary Power Device EF: MUA: Make Up AirIntelli-HoodVariable Frequency DriveTouchpadAuxiliary TouchpadExhaust Fan3

IV.Diagnostics/Troubleshootinga. Touchpad Display (TP)Fault Description Temp Fault Optic Fault 4Items to CheckMake sure that the sensors are clean. It is notalways necessary unless it has a largeamount of grease or build up.Check the connections that go from thetemperature probe to the Hood Controller.Check for any damaged components.Check that the number of temp sensorsinstalled matches the number of tempsensors programmed. Under menu hit Status(1) and go to hood controllers (3) and hitenter. If a temperature sensor is notconnected properly or does not work then itwill show as “missing”.Check Temperature offsetOn the hood controller there are differentports that can be used to connect the cablesfor temperature sensors, swapping those mayhelp to get rid of the fault.Check if temperature sensor resistance isapproximately 100 Ohms.Cycle power to the unit.Verify no obstructions to optic sensor infraredbeam (Ansul Pipes, pots / pans, etc).Confirm sensor lenses are clean.Make sure that the cables are connectedtightly on optic boards & on the hoodcontroller.Check alignment; use web application tocheck gain/voltage levels.If see attempts to calibrate when changingalignment, hardware is working properly.Using the keypad, go to Status and underhood controller verify that the optics are not

Variable Frequency Drive (VFD) Comm. Fault Touchpad Frozen Unable to enter System Configuration Touchpad not displaying correct devices (OR)Multiple Touchpads on same SC are frozen Light Button Works but TP is blank Fans Button not working 5missing.Cycle power to the unit.VFD type (ABB, Allen Bradley, Danfoss, etc)may not be identified correctly in Exhaust Fanor Aux Airflow programming.Check EF &MUA Aux Airflow status andconfirm VFD type is correct.Check display on VFD(s) for a fault (i.e. F5 orF13). Go to respective VFD and confirm if anyfault codes exist and troubleshoot inaccordance with VFD User’s Manual.System may have lost configuration orconfiguration file was corrupted, tech supportdownloads the configuration files and emails itto the technician working on site. The techwill drag it to the root directory of a USB andsave it as a ConfigurationFiles.zip file, poweroff the unit, place USB in port, cycle power onto the unit.Verify that the base board LED’s are lightingup. Power the system controller off, replacethe cell battery on the base board then powerback on.Confirm proper addressing of NetworkDevices (Hood Controllers and Touchpads).Enter menu screen on Touchpad, and withSystem Configuration selected, press and holdup/down arrows until text changes from redto blue (Approx 15 seconds)Check hardcoded address on Touchpad (TP),press and hold the up/down arrows on the TPfor 30 seconds. Change address to correctnumber. Power cycle System Controller tohardcode new address. Replacement TPmaybe defaulted to address of 1.Check programming of devices in service app.TP ribbon cable loose between boards (OR)boards not seatedCheck Exhaust Hood menu. Confirm on/off

Touchpad displaying incorrect Exhaust Fan (EF) &Make-Up Air (MUA) control is set to correct Touchpad addressCheck Exhaust Hood menu. ConfirmTouchpad Display NodeCheck corresponding EF's & MUA's devices toconfirm which TP is actually selectedb. System Controller (SC)Fault DescriptionLED’s not on LED on CPU Board not pulsing greenDigital Inputs / Outputs programmed but inactive Unable to Direct Connect via PCAuxiliary Input / Output (AIO) not working Lights not working 24VDC is not there System won’t turn on 6Items to CheckSystem may have lost input power.Check connectors from Power Brick to I/OBoard.Firmware may be corrupted.Verify DI/DO(s) are assigned to ExhaustHood.Verify Use DHCP set to No.Verify System Controller (SC) and VariableFrequency Drives (VFD’s) parity is set to 8-N1.Check fuse, if blown confirm lighting circuit isless than 15 amps.Confirm lighting leads are wired to SystemController (SC) or Auxiliary Light Controller(ALC) for control.Check 24VDC fuse.Check 24VDC connection from power board tobase board.Verify DI/DO(s) are assigned to exhausthoods.Check power dipswitch located near fuse is“ON”.Check for AC power, may be interrupted by ashunt trip or Ansul micro switch.Check circuit breaker panel.If power is at the System Controller (SC),check fuse.Check Power Brick to I/O Board connectionsPossible interlock with enable feature selected

Digital Input / Outputs are not controlling properhoods to Building Automation System (BAS) orWater Wash Panel.Confirm “Hood Groups” programmed correctlyc. Hood Controller (HC)Fault DescriptionLED not pulsingItems to CheckHood Controller (HC) may have lostcommunication to System Controller (SC).Confirm cable connections to other HC’s &SC.Confirm HC rotary switches are set to properaddress.If HC is last in the Hood Network string,confirm Terminal Resistor dip switch is on.Check for voltage drop issue.Check cable connections Hood Controller (HC) LED pulsing but notcommunicating correctly APU fan(s) not working d. Optic/Temp SensorFault DescriptionOptic Fault“Emitter Missing” White printed circuit Board“Receiver Missing” Blue Printed Circuit Board 7Items to CheckVerify no optic sensor obstructions in hood.Confirm sensors are clean.Make sure that the cables are connectedtightly on optic boards & on the hoodcontroller.Check alignment; use web application tocheck gain/voltage levels.If see attempts to calibrate when changingalignment, hardware is working properly.Using the keypad, go to Status and underhood controller verify that the optics are notmissing.Many smartphone cameras can see EmitterLight. Use phone camera to verify light is

emitting. Temp Fault Make sure that the sensors are clean. It is notalways necessary unless it has a largeamount of grease or build up.Check the connections that go from thetemperature probe to the HC.Check for any damaged components.Check that the number of temp sensorsinstalled matches the number of tempsensors programmed. Under menu hit Status(1) and go to hood controllers (3) and hitenter. If a temperature sensor is notconnected properly or does not work then itwill show as “missing”.On the hood controller there are differentports that can be used to connect the cablesfor temperature sensors, swapping those mayhelp to get rid of the fault.Verify temperature sensor resistance is about100 Ohms.Cycle power to the unit. Temp probe may be defective.Temp offset may be programmed incorrectly. Items to CheckConfirm Fault codes and refer to VFDOperations Manual. Temperature not measuring correctlye. Variable Frequency Drives (VFD’s)Fault DescriptionDepends on VFD type8

f. Exhaust Fans (EF’s)Fault DescriptionEF will not run EF has high current draw EF is running, but low to no air flow EF has an over voltageEF are running at 100%, but the MUA not running Items to CheckConfirm no faults at the Variable FrequencyDrive (VFD).Verify disconnect on the roof is turned on.Confirm motor rotation is spinning in thecorrect direction.Confirm actual condition of the motor. Belttension correct or general cleaning performed.Grease filters may need to be cleaned.Check belt on fan, it may be broken or loose.Obstruction in the duct.If installed, dampers stuck shut.Duct cleanout removed.Check for condensation in the disconnect.System Controller (SC) has lost power(Firemode)Possible override interlock to VariableFrequency Drives (VFD’s) from other controlsources if power is present and SystemController (SC) is operating.g. Make-Up Air (MUA) InterlockFault DescriptionMUA will not turn on System will not speed up when call for heat (OR) callfor cool 9Items to CheckConfirm start/stop from a 24VDC relay orinternal relay is connected from the SC to thecorrect terminal points on the MUA controlcircuit.Confirm closure is received at the SystemController (SC) for the correct terminal pointsof the Make-Up Air (MUA). (Generally afterthe Outdoor Air Temperature Sensor butbefore the Low Air Pressure switch).

h. Building Automation System (BAS) & BACnetFault DescriptionBAS cannot discover System Controller (SC)BAS cannot discover Exhaust Fan (EF) & Make-Up Air(MUA) data Items to CheckCheck Ethernet cable and port connection. Confirm IP address in the About Screen. Check IP settings are configured per site’s ITrequirements in the System Menu. Static IP(If not using DHCP), Netmask, Gateway,Domain Name System (DNS) Server 1, DNSServer 2Destination Network (DNET) number mightneed to be changed from 1 to a uniquenumber to avoid data collision i. Auxiliary Input / Output (AIO)Fault DescriptionAIO won’t work 10Items to CheckCheck connections, 24VDC and digital commsfrom System Controller (SC) to AIO.Confirm device exists in configuration,configuration settings and associated AUX airflows programmed and their associateddevices providing speed reference.Confirm parity in SC and Variable FrequencyDrives (VFD’s) is set to 8-N-1.Confirm dip switch on module set to“Normal”

j. Auxiliary Light Controller (ALC)Fault DescriptionALC won’t work Items to CheckCheck Ethernet cable and port connection.Confirm light controller address selected ontouchpad for lights operation.Confirm device exists in configuration.Confirm lighting circuit is connected to ALCfrom control.k. Auxiliary Power Device (APD)Fault DescriptionAPD is not boosting signal 11Items to CheckCheck circuit breaker.Check connections.Check for power.

Troubleshooting Guide I. About this Document The purpose of this document is to provide basic troubleshooting techniques for the Intelli-Hood Kitchen Control System. The intended audience of this document is the end user of the system: the building owner, kitchen manager, kitchen staff, or maintenance technician. II. Related Documents

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