Melink Intelli-Hood User manual

Melink Corporation [phone] www.melinkcorp.com
INSTALLATION MANUAL
MELINK
Intelli-Hood Controls
®
®

Melink Corporation [phone] www.melinkcorp.com
Table of Contents
2
Step Installation Page Contractor
1 Install I/O Processor 4Electrical
2 Install Electronic Motor Starter 6Electrical
3 Install Keypad 8Mechanical
4 Install Exhaust Temperature Sensor 9Mechanical
5 Install Optic Sensors 13Mechanical
6 Install Air Purge Unit 17Mechanical
7 Install Cables 18Mechanical
8 Install Options (if applicable) 23Mechanical
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Tools & Materials Required
Materials Required
●Suitable fasteners for mounting the I/O Processor and Electronic Motor Starter:
▫ hollow cinder block (3/16” toggle bolts)
▫ concrete or filled cinder block (lead anchors 1/2” dia. with 1/4” x 1-14” lag screws)
▫ drywall (3/16” toggle bolts)
▫ plywood (#8 X 1-1/4” wood screws)
▫ metal back-plate (#8 X 1-1/4” sheet metal screws)
●Conduit and wire for wiring the I/O Processor and Electronic Motor Starters
Tools Required
●Drill and Drill Bits (Cobalt is best for stainless steel) - bit sizes: 1/8” & 1/4”
●Hole Cutter or Punch for Stainless Steel with cutter sizes: 1-1/2” & 1-1/4”
●Adjustable Pliers and Adjustable Wrench
●Screwdrivers - Straight & Phillips, Large and Small
●Wire Cutter and Wire Stripper
●Measuring Tape and Level
●Step Ladder
Note: All high voltage wiring to be completed by trained service personnel. (Local code
may require a licensed electrician.)
3
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Install I/O Processor
For retrofits, the I/O Processor is
typically mounted above the hood.
Select a loc ation t hat is
easily accessible and close to
where the Keypad will be mounted.
Ideally, you should secure it to a
wall. DO NOT PENETRATE THE
HOOD EXHAUST PLENUM.
For new construction, the hood
manufacturer typically provides a
utility cabinet in which to mount
the I/O Processor. If the hood
has a utility cabinet with extra
space, mount the I/O Processor
(and Electronic Motor Starters)
there.
A
4
Select I/O Processor Location
1
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Turn OFF the I/O Processor
power switch before wiring.
Also turn off the breaker
feeding this circuit.
Install I/O Processor
B C
115V or 230V
ON
OFF
Wire Connections Inside I/O Processor
D
Retrofits:
You do not need to use
these output terminals
if you want to use the
existing hood light
switch to control the
hood lights. Otherwise,
wire the same as for
new construction.
115/230V
INPUT
GND N L GND N L
115/230V (15A)
LIGHTS (OUTPUT)
New Construction & Retrofits:
Main Input Power
from Hood Light Circuit
115/230 VAC
New Construction:
Outgoing Power to Hood Lights
115/230 VAC
15 Amps max
For both New Construction & Ret-
rofits, wire the I/O Processor using
the hood light circuit. The circuit
must be either 115V or 230V, at
50-60Hz.
5
1
Turn Off Power Switch Wire I/O Processor
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All wiring must comply with the National Electric Code (NEC
and local code requirements.
Install Electronic Motor Starter
For new construction, the Intelli-Hood includes an Electronic Motor Starter (also referred to as
Variable Frequency Drive or VFD) for each kitchen exhaust and make-up air fan. This type of
starter is for use with 3-phase motors only. It not only turns the fans on and off, but also
varies the speed of the motors by varying the output frequency and voltage. Therefore, you do
not need a conventional magnetic motor starter with our system. Caution: If you have a
tempered make-up air unit, then the control circuit for the heating system must be fed by a
separate power source and NOT from the Electronic Motor Starter! The output of the Electronic
Motor Starter must be wired to the motor ONLY and NOT to a transformer or any part of a control
circuit!
If there is a make-up air unit, then the Electronic Motor Starter for this unit must be interlocked
with the fire suppression micro-switch so that this fan turns off in the event of a fire. This is
accomplished by connecting a low-voltage cable between designated terminals on the Electronic
Motor Starter (01 and 04 for Allen-Bradley) and the Normally Closed (NC) terminals on the micro-
switch. Caution: With variable frequency drives, there must be a separate conduit run for the
output of each VFD (inputs may be run together if desired). If this is not done, there is a strong
probability of problems due to line interference and inaccurate motor control.
For retrofits, the only difference between new construction and retrofits is that on retrofits you
will already have conventional magnetic motor starters installed. In most cases, it is
recommended that you install the Electronic Motor Starters on the output side of the existing
starters. This will enable the cooks/chefs to use the existing hood fan (and light) switch and not
have to change their habits. This will also allow you to keep the existing circuit intact between
the magnetic starter for the make-up air unit and the fire suppression system micro-switch.
6
2
A Verify Electronic Motor Starter Wiring
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3-phase
input from
breaker or
magnetic
motor starter
The location must be relatively free of dirt,
grease, and water. The ambient tempera-
ture must be between +14 degrees F and
+122 degrees F. There should be 5” of
clearance on the top and bottom and 1” on
the sides for adequate ventilation/cooling.
Install Electronic Motor Starter
C
1”
5”
5”
1”
E D
3-Phase
Input
3-Phase
Output
Mount each VFD with appropriate fasteners.
Then install separate conduit for the input
and output power wiring to prevent electrical
interference between the conductors.
L1 L2 L3 U V
BR+
W
G
BR-
3-phase
output to
fan motor
Remove the VFD top cover and connect
the line voltage wiring to the VFD input
power terminal block as shown above.
Then connect the output power from the
terminal block to the respective fan motor
on the roof. The ground wire must be a
minimum of 14 AWG and as short as pos-
sible. The output wiring for each VFD
MUST be in a separate conduit run.
7
2
For retrofits, each VFD is typically
mounted on the output side of the exist-
ing motor starter, which is often located
in an electrical room, above the hoods,
or inside a utility cabinet. For new con-
struction, the hood manufacturer typi-
cally provides a utility cabinet in which to
mount the VFDs.
Select VFD Location Check VFD Location
Mount VFD Wire VFD
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B

Mount the Keypad to the junction box and
secure the cover plate with 4 screws. Peel
and stick the top and bottom of the label to
cover the screws.
Plug the connector into the receptacle on
the back of the Keypad.
C
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Before removing the switch
cover plate, turn off the circuit
breaker.
For retrofits, if you want to replace the
existing fan and light switch with our
Keypad, remove these switches from the
junction box. Then remove the existing
wires to make room for the Keypad Cable.
Run the Keypad Cable inside the existing
conduit and leave approximately 5 inches
of slack inside the junction box. You will
connect the other end of the Cable to the
I/O Processor in Step 7-D.
B
Install Keypad
A
D
8
3
Run Keypad Cable
Plug In Cable Mount Keypad
Remove Existing Switches
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L ≤ 24” (600mm) L ≤ 24” (600mm)
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4
5
Hood 1 (Top View)
Install Exhaust Temperature Sensor
B
Install one (1) Temperature Sensor
per exhaust duct, if the length of the
duct is less than 24”. In most cases
this will mean one Temperature
Sensor per hood.
In some cases, this will mean two
Temperature Sensors per hood.
If the length of the duct is more than
24”, then install two Temperature
Sensors in order to obtain a better
average reading.
A
Duct Top View
L < 24” (600mm)
L ≥ 24” (600mm)
Hood 2 (Top View)
Hood 3 (Top View)
9
4
Determine Number of Sensors
Select Location for Mounting Sensor
Select a location for mounting each
Temperature Sensor. The tip of the
sensor should be inside the center
of the duct to sense the average
temperature. For most installations,
proceed with steps C-F on page
10. An alternate mounting proce-
dure is described in steps C-J on
pages 11 and 12.
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4
5
Probe Protector
Temperature
Probe
Sealfast Fitting
Shielded Receptacle
Protective Sleeve
D
F
Mount each Temperature Sensor from the
inside of the duct. Insert the lock washer
and tighten the nut from the outside of the
duct, then re-attach protective sleeve and
strain relief.
1-1/4”
(32mm)
Drill or punch a 1-1/4” (32mm) diameter
hole at the proper location for each Tem-
perature Sensor.
C
Each Temperature Sensor should be
located as closely to the top of the hood as
possible for easy access and cleaning.
E
10
Install Exhaust Temperature Sensor
Strain Relief
4
Select Location on Duct Side View of Sensor
Drill Hole in Duct Mount Sensor
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D
Using the gasket as a template, mark the
hole locations for each Temperature Sensor.
Drill or punch a 2-1/4” (57mm) diameter
hole and drill (4) 3/16” holes at the marked
locations.
3/16” (5mm)
2-1/4” (57mm)
C
E
F
In cases where the inside of the duct is not
accessible, this alternate mounting proce-
dure may be used. Begin with steps A-B,
then continue with these alternate steps C-J.
11
Install Exhaust Temperature Sensor
Probe Protector
Temperature
Probe
Flange Fitting
Gasket
Bushing
Protective Sleeve
Strain Relief
Shielded
Receptacle
Select Location on Duct Side View of Sensor
Mark Hole Locations Drill Hole in Duct
4
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H
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4
5
By reaching into the 2-1/4” hole, insert the
stud into the 3/16” hole from inside the
duct so that the threaded end is protruding
outward. Tighten the wing nut onto the
stud until its self-clenching base is securely
wedged into the hole. Repeat this step for
the other studs.
G
J
Place the gasket over the studs, followed
by the flange fitting. Tighten with the (4)
wing nuts using an adjustable wrench
until the unit is secure. Check around
the seal to make sure the flange is sitting
flush to the duct with no gaps.
Remove wing nut from each stud. Check to
be sure that all the studs are securely
wedged into each hold. If any feel loose, re-
tighten the wing nut onto the stud using a
wrench. Remove all remaining wing nuts.
12
Install Exhaust Temperature Sensor
Insert Studs Tighten Studs
4
Mount Sensor
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of the cooking surface and the middle of the
hood filters. The Optic Sensors should be
mounted along that virtual line inside the
ends of the hood. (This is typically about 3”
from where the fitter bank meets the top of
the hood.) Also, the Optic Sensors must be
mounted directly across from each other.
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5
3
Install Optic Sensors
B A
D
C
Make sure there are no obstructions at
least 10” (254mm) from where you need to
penetrate the top of the hood. Also, make
sure the location will not cause the Optic
Sensor beam to be obstructed by anything,
such as fire suppression piping.
To determine
where to install
the Optic Sen-
sors, imagine a
virtual line be-
tween the front
1-1/2”
13
3-1/4”
Approx. 3”
is typical.
Check Hood Select Sensor Locations
Mark Hole Locations Drill Holes in Hood
5
Then drill or punch a 1-1/2” (38mm) hole at
these same locations.
The hole locations need to be centered 3-1/4”
(83 mm) from the inside ends of the hood.
Drill a small pilot hole to mark these exact
locations.
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5
3
Nut
Lock Washer
Gasket
Threaded
Coupling
Compression
Nut
Insert the Purge Pipes inside the
Fittings with the notch positioned
above the hood. Tighten the Fitting
temporarily, until the Optic Sensors
are mounted.
F
Above Hood
Inside Hood
E
14
Install Optic Sensors
5
Install Fittings
Install Purge Pipes
Install the Fittings at the hood
penetrations in the order shown.
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5
3
Approx. 3”
is typical.
H G
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Use the base of each Optic Sensor as a
template to mark the location for two
mounting holes. Be sure to locate the
Optic Sensor in the virtual line mentioned
in step 5-B. Drill 3/16” holes.
Mount the base with two stainless
steel screws. The screws can be
located inside or outside of the
hood, depending upon the
location of the hood. If the hood is
located against a wall, then self-
tapping screws from the inside
must be used. If the hood is not
located against a wall, then use
the machine screws, washers and
nuts provided.
15
Install Optic Sensors (Optic Enclosures)
Base
Disengage Optic Sensors
5
Mount Optic
Sensor Base
Disengage the cover from the base on each
Optic Sensor. One has a circuit board
labeled „Emitter‟, and the other is labeled
„Receiver‟. The ‘Receiver’ should be
mounted closest to the I/O Processor.
Mark Hole Locations
Cover
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J

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Remove the Optic Cables from the box. Insert the end of one cable with the small anti-
snag boot up through the purge pipe from the optic housing with the Emitter Board. Plug in the
cable end with the large anti-snag boot into the jack on the Emitter Board and push any excess
slack up the purge pipe. Mount the cover onto the base. Repeat with Receiver Board.
Emitter
16
Install Optic Sensors
Receiver
L
Install Optic Cables
Run the cables up each Purge
Pipe and verify that they are
located inside the notches
before installing the APUs.
Run Cable Up Purge Pipes
5
K
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17
Install Air Purge Units
6
Remove the lids from each APU box to
prepare for step 7.
Plug the Optic Cables into any receptacle on the header board inside each APU. Then
run a cable from APU box to APU box.
Attach an APU to each Purge Pipe and
tighten the compression fitting.
A Attach APU to Purge Pipe Remove APU lids B
Optic Cables
Plug In Optic Cables
C
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C
Remove a cable from its package and plug
one end into the receptacle on the bottom
of one VFD.
Then plug the other end of the cable into
the receptacle marked „VFD‟ on the side of
the I/O Processor.
A
B
If you have multiple VFDs, plug the
remaining VFDs to one another with
additional cables, keeping only one
VFD plugged to the I/O Processor.
18
Install Cables (Electronic Motor Starter)
7
Plug Cable Into VFD Plug Into I/O Processor
Connect VFDs
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...and run it to the I/O Processor on the
other side of the cabinet.
E
Inside the Utility Cabinet, take the Keypad
Cable already connected on one end ...
19
Install Cables (Keypad)
D
Utility Cabinet
7
Find Keypad Cable Plug Into I/O Processor
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Remove the Temperature Cable from its
package. Connect one end to the Tempera-
ture Sensor receptacle, and then tighten the
strain relief.
20
Plug Cable into
Temperature Sensor
Plug Into I/O Processor OR APU
Install Cables (Temperature Sensor)
7
F
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G
If there are NO Optic Sensors, connect the
other end of the cable to the receptacle for
the respective hood on the I/O Processor.
If there ARE Optic Sensors, connect the
other end to any receptacle in the APU
box. Repeat as necessary for each hood.
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