user's manual - jamesway · 2019. 8. 9. · jamesway incubator company inc. 30 high ridge...

TM

PS501 User's Manual

MANPS501Revision 1

Jamesway Incubator Company Inc.30 High Ridge Court

Cambridge, Ontario, Canada N1R 7L3

tel: (519) 624-4646fax: (519) 624-5803

email for customer service:[email protected]

This book and its contents are the property of the Jamesway Incubator Company Inc. Reproduction in whole or in part, by any means, without permission

of Jamesway Incubator Company Inc. is prohibited. © 2013 Jamesway Incubator Company Inc.

PS501 Multi-Stage Controller

User’s Manual

MANPS501Revision 1

Contents

Introduction ..................................................................................................................................................... 1Unpacking the Controller............................................................................................................................... 2Technical Specifications ................................................................................................................................ 4Component Overview ................................................................................................................................... 5

The Control Box and Key ......................................................................................................................... 5Controller Identification ............................................................................................................................ 5Controller Safety Warning Labels ............................................................................................................ 6Temperature and Humidity Sensor .......................................................................................................... 6

Mounting the Control Box .............................................................................................................................. 7Incubators ................................................................................................................................................ 7Hatchers .................................................................................................................................................. 7Wiring ....................................................................................................................................................... 8

Mounting the Temperature and Humidity Sensor ........................................................................................ 8

Initial Set-up .....................................................................................................................................................11Preliminary Machine Parameters ....................................................................................................................................11

Machine Type ..........................................................................................................................................11Alarm Set-up ...........................................................................................................................................12Fan Motor Off Switch(Incubators) ...........................................................................................................13Voltage Check ........................................................................................................................................13

Monitoring the 24-Hour Dry Run .................................................................................................................14Pre-Run ...................................................................................................................................................14

Temperature and Humidity Sensor Set-up ........................................................................................14Temperature and Humidity Settings ..................................................................................................15Dry Run ..............................................................................................................................................15

Egg Turn Test (Incubators) ...........................................................................................................16

Working with the Controls ..............................................................................................................................17The Display ..................................................................................................................................................17

Basic Button Function .............................................................................................................................18Controls and Indicators ...........................................................................................................................18

Power Switch ...................................................................................................................................18Common Alarm Lamp ........................................................................................................................18Fan Switch on the Control Box .........................................................................................................18

In the Incubator .............................................................................................................................18Alarms .................................................................................................................................................... 20

LEDs ................................................................................................................................................ 20Common Alarm Lamp ....................................................................................................................... 20Audible Alarms .................................................................................................................................. 21Alarm Bypass .................................................................................................................................... 21

Alarm Types ................................................................................................................................................ 22High Temperature ................................................................................................................................. 22Low Temperature .................................................................................................................................. 22High Humidity ........................................................................................................................................ 22Low Humidity ........................................................................................................................................ 22Dry Wick ................................................................................................................................................ 22Fan Failure ............................................................................................................................................ 22Maintenance ......................................................................................................................................... 22Turn Failure ........................................................................................................................................... 22Door Open ............................................................................................................................................ 22

System Status ............................................................................................................................................. 23Main Heater (Incubators) or Heater (Hatchers) ..................................................................................... 23Auxiliary Heater (Incubators) ................................................................................................................. 23Cooling (Incubators) .............................................................................................................................. 23Primary Cooling (Chicken Hatchers) .................................................................................................... 23Secondary Cooling (Hatchers) .............................................................................................................. 23Spray ...................................................................................................................................................... 23Damper Close ........................................................................................................................................ 23Damper Open ........................................................................................................................................ 23Damper Fully Closed.............................................................................................................................. 23Damper Fully Open ................................................................................................................................ 23Turn Valve (Incubators) .......................................................................................................................... 24All Racks Left ......................................................................................................................................... 24All Racks Right ....................................................................................................................................... 24Turn in Progress ..................................................................................................................................... 24

Command Buttons ...................................................................................................................................... 25Temperature Setpoint ............................................................................................................................. 25

Adjusting the Temperature Setpoint ................................................................................................. 25Humidity Setpoint ................................................................................................................................... 25

Adjusting the Humidity Setpoint ........................................................................................................ 25Error Messages ..................................................................................................................................... 25Alarm Acknowledge ............................................................................................................................... 26

Exceptions ........................................................................................................................................ 26Alarm Test .............................................................................................................................................. 26Manual Egg Turn (Incubators) ............................................................................................................... 26Spray Test (Hatchers) ............................................................................................................................ 26

Function Button ........................................................................................................................................... 27Temperature and Humidity Calibration .................................................................................................. 27Temperature Units .................................................................................................................................. 27

Changing the Temperature Readout Units ....................................................................................... 27Hatchcom Address ................................................................................................................................. 27

Changing the Address ...................................................................................................................... 27Alarm Silence Delay ............................................................................................................................... 28

Changing the Delay Time ................................................................................................................. 28Rack Turn Interval .................................................................................................................................. 28

Programming the Rack Turn Interval ................................................................................................ 28

Routine Maintenance ..................................................................................................................................... 29Control Box.................................................................................................................................................. 29

Procedure .............................................................................................................................................. 29Temperature and Humidity Sensor ............................................................................................................. 29

Weekly Procedure .................................................................................................................................. 29Reservoir .......................................................................................................................................... 29Wick .................................................................................................................................................. 29To Install a Wick ................................................................................................................................ 29

Three Month Procedure ......................................................................................................................... 29Probes ............................................................................................................................................... 29

Calibration, General Considerations ...................................................................................................... 30Environment ...................................................................................................................................... 30Equipment ......................................................................................................................................... 30Procedure ......................................................................................................................................... 30

Temperature Calibration ......................................................................................................................... 31Calibrating the Temperature Readout ............................................................................................... 31

Humidity Calibration ............................................................................................................................... 31Calibrating the Humidity Readout ..................................................................................................... 31

The Display ................................................................................................................................................. 31High Temperature Test ........................................................................................................................... 32Low Temperature Test ............................................................................................................................ 32High Humidity Test ................................................................................................................................. 32Low Humidity Test .................................................................................................................................. 32Alarm Test .............................................................................................................................................. 32Fan Motor Off Switch Test ..................................................................................................................... 32Turn Failure Test(Incubator) .................................................................................................................. 32Power Off Test ....................................................................................................................................... 32

Replacement Parts ........................................................................................................................................ 35Incubator Control Box ................................................................................................................................. 35

Boards .................................................................................................................................................... 35Incubator Control Box ........................................................................................................................... 36

Hatcher Control Box .................................................................................................................................... 37Boards .................................................................................................................................................... 37Hatcher Control Box ............................................................................................................................... 38

Temperature and Humidity Sensor Accessories ................................................................................................................................................. 39Accessories ................................................................................................................................................. 40

Backup Alarm ......................................................................................................................................... 40High Temperature Backup Alarm ............................................................................................................41Battery Operated Circuit Tester ..............................................................................................................41Digital Thermometer ...............................................................................................................................41Incubator Turn Tester ..............................................................................................................................41Velometer Air Flow Meter ........................................................................................................................41Volt/Ampere Probe ..................................................................................................................................41

Wiring ............................................................................................................................................................. 43Incubator - Control Box Layout ................................................................................................................... 43Incubator - Fans and Heaters...................................................................................................................... 44Incubator - Air and Water Valves ................................................................................................................. 45Incubator - Interior Lights ............................................................................................................................ 46Incubator - Damper System ........................................................................................................................ 47Incubator - Motor Off Switches ................................................................................................................... 48Incubator - Fan and Light Switches ............................................................................................................. 49Incubator - Fail Safe Turning ...................................................................................................................... 50Incubator - Temperature and Humidity Sensor, DIP Switch Settings ..........................................................51Incubator - Alarm Connections ................................................................................................................... 52Hatcher - Control Box Layout ...................................................................................................................... 53Hatcher - Fans and Heater .......................................................................................................................... 54Hatcher - Air and Water Valves ................................................................................................................... 55Hatcher - Damper System ........................................................................................................................... 56Hatcher - Door Switches ............................................................................................................................. 57Hatcher - Temperature and Humidity Sensor, DIP Switch Settings ............................................................ 58Hatcher - Alarm Connections ...................................................................................................................... 59Incubator - High Voltage.............................................................................................................................. 60Incubator - Low Voltage .............................................................................................................................. 61Hatcher - High Voltage ................................................................................................................................ 62Hatcher - Low Voltage ................................................................................................................................. 63External Audible Alarm .............................................................................................................................. 64

Installation .............................................................................................................................................. 64

Fibre Optic Network ....................................................................................................................................... 65Fibre Optic System ..................................................................................................................................... 65Fibre Optic Cabling and Hubs ..................................................................................................................... 65

General Installation Guidelines .............................................................................................................. 66Polishing Instructions ............................................................................................................................. 67Splicing Instructions ............................................................................................................................... 68Troubleshooting Cable Performance ................................................................................................................................ 69

How to Connect to Hatchcom ..................................................................................................................... 69

Machine Problems ......................................................................................................................................... 71Error Messages ........................................................................................................................................... 72Mechanical Checklist .................................................................................................................................. 72

Heat ........................................................................................................................................................ 72Humidity ................................................................................................................................................. 73Egg Turn ................................................................................................................................................. 73

Basic Troubleshooting ................................................................................................................................. 73Visual Inspection ................................................................................................................................... 73

Troubleshooting Charts ............................................................................................................................... 73High Temperature Alarm ........................................................................................................................74Low Temperature Alarm ......................................................................................................................... 75High Humidity and/or Dry Wick ............................................................................................................. 76Low Humidity ......................................................................................................................................... 77Fan Failure Alarm (Incubator) ................................................................................................................ 78Damper Not Opening or Closing ............................................................................................................ 79Door Alarm (Hatcher) ............................................................................................................................. 80Egg Turn Failure (Incubator) .................................................................................................................. 81Blower Does Not Work ........................................................................................................................... 82Erratic Display Panel Readings ............................................................................................................. 83

Glossary .......................................................................................................................................................... 85

PS501 Controls, User’s Manual 1

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This manual is intended as a guide for those who operate the PS501 Multi-Stage Controller for Jamesway incubators and hatchers.

In order to assist users who may not have an electron-ics background, the information in this manual is presented in plain language. Topics covered include an overview of the components and their replacement parts, how to program and use the controls as well as perform routine maintenance and troubleshoot problems. Jamesway recommends that you become familiar with this manual prior to operation and use of these controls. Maintenance and troubleshooting should only be done by qualified personnel.

Jamesway provides technical assistance for your controls as well as replacement parts. When in doubt, contact Jamesway.

PS501 Control Box, Incubator

PS501 Control Box, Hatcher

2 PS501 Controls, User’s Manual

UNPaCkING the CONtROlleR

Your PS501 Multi-Stage Controller has been shipped as one of the following:1. Controls supplied with a multi-stage incubator.2. Conversion kit to upgrade a multi-stage incubator.3. Controls supplied with a PX hatcher or 2 Door

hatcher.4. Conversion kit to upgrade a PX hatcher or 2 Door

hatcher.

Please carefully unpack your controls, check parts against the parts sheet and familiarize yourself with them. All packs contain the PS501 Multi-Stage control box, the key, the mounting bracket, the temperature and the humidity sensor (including its mounting bracket, reservoir and wick), tubing and hardware. Your controller may include the PTA669 communications module if you have purchased the networking option. It will be packed separately.

Incubator Controller - PTA692

Mounting Brackets (2)

Control Box Key

PS501 Control Box

Temperature and Humidity Sensor - includes bracket, baffle, reser-voir, reservoir bracket, and probes. Mounting hardware included in hardware pack Wicking–3 feet (39 cm)Tubing

Hardware

S/N

Optional Communications Module PTA669


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Hatcher Controller - PTA694

Mounting Brackets (2)

Control Box Key

PS501 Control Box

Temperature and Humidity Sensor - includes bracket, baffle, reser-voir, reservoir bracket, and probes. Mounting hardware included in hardware pack Wicking–3 feet (39 cm)Tubing

Hardware

Refer to the manual in all the cases where this symbol is used on the equipment.

Warning: If the equipment is used in the manner not specified by Jamesway the protection provided by the equipment may be impaired.

!


teChNICal SPeCIFICatIONS

PS501 Controller: General

For Indoor user only

Operating Temperature 0-50°C

Relative Humidity 10-95%

Degree of Protection IP54 (All new drilled holes for cable entries must use proper “liquid tights”.)

PS501 – Incubator

Volts 208 – 240 VAC

Frequency 50/60 Hz

Phase Single

Power 9,200 W

electrical Requirements in the Building’s Distribution Panel for Incubator

Total connected load at 230 V is 42 A. Power supplied to the incubators may be in any of the following configurations:

1. 230 V, single phase, 3 wire, 60 Hz,

2. 230 V, single phase, 2 wire, 50 Hz, or

3. 230 V, single phase, 2 wire, 60 Hz.

Each incubator also requires:

1. One non-fused grounded neutral lead,

2. One 50 A (for 230 V operation), or 60 A (for 115 V operation) circuit breaker protecting ungrounded load carrying conductors.

With 230 V motors, the start-up load* is 42 A, running load is 27 A

With 115 V motors, the start-up load* is 53 A, running load is 38 A

PS501 – hatcher

Volts 208 – 240 VAC

Frequency 50/60 Hz

Phase Single

Power 3,425 W

electrical Requirements in the Building’s Distribution Panel for hatcher

Total operating load at 230 V is 13 A.

Power supplies to the hatcher may be in any of the following configurations:

1. 230 V, single phase, 3 wire, 60 Hz,

2. 230 V, single phase, 2 wire, 50 Hz, or

3. 230 V, single phase, 2 wire, 60 Hz.

Each hatcher requires the following:

1. One non-fused grounded neutral lead,

2. One 20 A circuit breaker protecting the ungrounded load carrying conductor.

With 230 V motors, the running load is 13 A

With 115 V motors, the running load is 17 A


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COMPONeNt OveRvIeW

the CONtROl BOx aND key

Key Entry to Control Box—Except during main-tenance, the control box should be locked. This will ensure that the seal is snug and thus prevent moisture and dirt from entering the box.

Power Switch—Power on (1), power off (0). When the power is on, the switch will lock the lid in place. For safety and optional controller function, ensure that the box is also key locked.

The Display is mounted on the lid of the PS501 control box. It functions both as a receiver of information and as a means of transmitting information. Parameters displayed are:1. Actual temperature and humidity 2. Temperature and Humidity setpoints 3. Alarm status 4. Heating, Cooling and Spray status5. Damper status 6. Turn status (incubators only) 7. Common Alarm lamp.

Fan Switch—The Fan switch is the grey toggle switch located on the bottom of the control box (left side). Refer to page 18 for further details.

Alarm Bypass Switch—The Alarm Bypass switch is the red toggle switch located one the bottom of the control box (right side). Refer to page 21 for further details.

CONtROlleR IDeNtIFICatION

Prior to installing the controller, ensure that the proper controller is being installed on the proper machine. The contollers identification label can be found on the right side.

Temperatureand Humidity

Input Buttons

Alarms

OutputStatus

Key Power Switch

Common Alarm Lamp

Alarm Bypass Switch

Fan Switch

Control Box

Item Part No. Description

1 ....... PB6019 ........ Incubator or ......... PB6020 ........ Hatcher

PS501 Controller Identification Label (Incubator shown)

JAMESWAY INCUBATOR CO. INC.

MODEL: PS501 - INCUBATORSERIAL NUMBER:WATTS: 9,200 W VOLTS: 208-240 VACPHASE: 1 CYCLE: 50/60 HZ

30 High Ridge Ct., Cambridge Ontario, N1R 7L3, Canada

PB6019


MODEL: PS500 - INCUBATOR

SERIAL NUMBER:

WATTS: 9,200 W VOLTS: 208-240 VAC

PHASE: 1 CYCLE: 50/60 HZ

30 High Ridge Ct., Cambridge Ontario, N1R 7L3, Canada

PB6019

1


MountingBracket

Water Reservoir

Reservoir Base

Humidity Probe with Wick

Temperature Probe

Baffle

Sensor

CONtROlleR SaFety WaRNING laBelS

There are a number of safety labels attached to the control box. Jamesway recommends that the qualified electrical personnel, who service the contoller, pay special attention to these labels and take appropriate precautions as required.

S/N

!


MODEL: PS500 - INCUBATOR NA

SERIAL NUMBER:

WATTS: 9,200 W VOLTS: 208-240 VAC30 High Ridge Ct., Cambridge Ontario, N1R 7L3, Canada

PB5862

!

teMPeRatURe aND hUMIDIty SeNSOR

The platinum sensor probes accurately evaluate the machine’s environment—actual temperature and actual humidity. This information is transmitted to the control box and is read on the display. The sensor comes with its mounting bracket and two probes, as well as a reservoir and wick for humidity readings.


1 ............................ PS501 Warning Label2 ............................ Disconnect Power Label3 ............................ Ground Label4 ............................ PS501 Replacement Fuse Label

Note: Jamesway recommends that only quali-fied electrical personnel install the controller, set the initial parameters and do the electrical checks.

1

2

3

4

Controller Safety Warning Labels


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MOUNtING the CONtROl BOx

After removing the old controls, it is best to mount the control box in the same position as the previous display (PT100) or the previous information panel (electromechanical controls). Consideration should be given to the use of existing mounting holes. Drill new holes only as necessary.

After mounting, ensure that all metal filings and other debris are removed from the inside of the control box. Seal all conduits with silicone to prevent moisture from entering the box.

INCUBatORS

Insert the grommets (exterior to interior) in the pre-drilled holes in the in the control box. Mount the box to the bracket using hex head bolts, washers and nuts. Centre the assembly on the header and secure with self-drilling screws.

hatCheRS

Insert the grommets (exterior to interior) in the pre-drilled holes in the in the control box. Mount the top of the box to the bracket using hex head bolts, washers and nuts. Centre the assembly and mount the bottom of the box to the header and bracket using hex head bolts, washers and nuts. Secure the bracket to the header with self-drilling screws.

Mounting the Incubator Control Box

Mounting the Hatcher Control BoxItem Part No. Description

1 ............................ Roof Panel, Incubator2 ............................ Front Panel, Incubator3 ............................ Header, Hatcher4 ............................ Extrusion5 ....... MB20138 ..... Mounting Bracket, Incubator ......... MB20141 ...... Mounting Bracket, Hatcher6 ....... PTA692 ........ Incubator Control Assembly ......... PTA694 ........ Hatcher Control Assembly7 ....... P2710 .......... Grommet, 1/4 in. ID8 ....... P6375 .......... Flat Head Screw

Grommets - exterior to interior

1

2

4

56

78

910

11

Grommets - exterior to interior

3

4

6

78

910

11

5

12

Note: Jamesway recommends that only quali-fied electrical personnel install the controller, set the initial parameters and do the electrical checks.

1/4 in. - 20 X 3/4 in.9 ....... P454 ............ Flat Washer, 1/4 in. 10 ..... P6119........... Lock Nut, 1/4 in. - 20 11 ..... P6082 .......... Self-drilling SS Screw, #10 x 1/2 in.12 ..... P5504 .......... Hex Head Bolt, 1/4 in. x 2-1/2 in.


WIRING

Since the PS501 was designed to fit all multi-stage machines, wiring in the controller differs. Wiring diagrams for all electrical configurations, can be found starting on page 43. Please contact Jamesway if you require assistance.


1 ....... MB16163 ...... Probe Mounting Channel2 ....... MB16261 ...... Probe Baffle3 ....... PB4077 ........ Wick4 ....... AB5672 ........ Reservoir Assembly5 ....... MB15047 ...... Reservoir Holder6 ....... P2730 .......... Rubber Stopper7 ....... P6082 .......... Self-drilling SS Screw, #10 x 1/2 in.

3-1/2 inches(90 mm)

1

72

3

4

5

67

7

MOUNtING the teMPeRatURe aND hUMIDIty SeNSOR

Remove the old sensor or thermostat control board.

Situate the new sensor on the centre post directly behind the control box (inside the cabinet) for all incubators and 2-Door Hatchers. For PX Hatchers, the sensor will be mounted on the right hand corner post. (This is the same position as the previous PT100 sensor , and the previous thermostat board for electromechanical controls for hatchers.)

If the previous sensor was not mounted in this position (E/M incubators), drill a 3/8 inch (9.5 mm) hole through the roof. Centre the hole with the Centre Post and about 1/8 inch (3 mm) in from the Centre Post.

Drill an appropriate sized hole in the control box. This hole will provide entrance for the sensor wiring.

Insert a liquid tight connector (not provided) in the control box hole as well as the roof hole.

Slide the wires up the tube through the liquid tights and into the control box. Attach the probes to the Probe Mounting channel.

Apply silicone around the probe/mounting channel connection – both inside and out.

Centre the Probe Mounting channel on the Centre Post (right hand Centre Post for PX Hatchers) and butt the top of the channel up against the ceiling. Secure with self-drilling screws.

Warning: Disconnect the power from the mains before accessing the inside of the controller.

Warning: Replace the protective conductor after removal.


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1 ....... MB16163 ...... Probe Mounting Channel2 ....... MB16261 ...... Probe Baffle3 ....... PT1141 ......... Probe Assembly4 ....... PB4529 ........ Liquid Tight Connector5 ....... P4161 ........... Clear Tubing, 3/8 in.

Position the Reservoir holder 3-1/2 inches (90 cm) below the Probe Mounting channel. Secure with self-drilling screws.

Mount the Probe baffle into the pre-punched holes in the Probe Mounting channel using self-drilling screws.

Apply silicone around the roof hole and the control box connection – both inside and out.

For wiring, refer to page 51 for incubators and page58 for hatchers.

1

5

2

34

PS501 Multi-Stage Controller, User’s Manual 11

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Prior to initial use, it is practical to check and/or set up the following parameters for your machines—Machine type, Alarm set-up and the Fan Motor Off switch. It is also advisable to do a voltage check followed by a monitored 24-hour dry run.

PRelIMINaRy MaChINe PaRaMeteRS

MaChINe tyPe

DIP switch settings 7 and 8 on the SMA109S board (located on the lid of the control box) are used to set machine type. Four selections are allowed: incuba-tor, incubator without turn alarm, chicken hatcher or turkey hatcher.

Check the settings or set accordingly, if changes are required.

Machine type DIP Switch 7 DIP Switch 8

1. Incubator* ON ON

2. Incubator with-out Turn Alarm

OFF ON

3. Chicken hatcher**

ON OFF

4. Turkey Hatcher OFF OFF

* The default setting for the Incubator is (ON/ON).**The default setting for the Hatcher is (ON/OFF).

Warning: Jamesway recommends that only qualified electrical personnel set the initial parameters and do the electrical checks. Some circuits are energized with 220 Volts. They will cause serious shocks, injury or death if touched. Before setting the parameters, ensure that the Main Switch is turned to OFF (0) and the power is locked out at the distribution panel.

Location of DIP Switch on the SMA109S Circuit Board (Control Box for Incubator shown)

S/N

SMA109S CIRCUIT BOARD(LEFT HAND CORNER)

OP

EN

1 2

3 4

5 6

7 8

HI TEMP CANCEL

FAN FAIL

TURN/DOOR

HIGH HUM

LOW TEMP

LOW HUM

MACH TYPE

ON

OFF

J1MODE 1 2 3

OFF ON

!

12 PS501 Multi-Stage Controller, User’s Manual

hatcher DIP Switch Settings 1 to 6

1ONOFF

High Temperature alarm can be silencedhigh temperature alarm cannot be silenced

2ONOFF

Fan Failure alarm is audibleFan Failure alarm is silent

3ONOFF

Door Open alarm is audibleDoor Open alarm is silent

4ONOFF

high humidity alarm is audibleHigh Humidity alarm is silent

5ONOFF

low temperature alarm is audibleLow Temperature alarm is silent

6ONOFF

low humidity alarm is audibleLow Humidity alarm is silent

* The default settings are in bold

Incubator DIP Switch Settings 1 to 6

1ONOFF

High Temperature alarm can be silencedhigh temperature alarm cannot be silenced

2ONOFF

Fan Failure alarm is audibleFan Failure alarm is silent

3ONOFF

turn Failure alarm is audibleTurn Failure alarm is silent

4ONOFF

high humidity alarm is audibleHigh Humidity alarm is silent

5ONOFF

low temperature alarm is audibleLow Temperature alarm is silent

6ONOFF

low humidity alarm is audibleLow Humidity alarm is silent

* The default settings are in bold

Location of DIP Switch and J1 on the SMA109S Circuit Board

alaRM Set-UP

DIP Switch settings 1 to 6 on the SMA109S board are used to set alarm sound parameters. Any or all alarms can be programmed to be silent or audible. Choices include whether the High Temperature alarm can be silenced (or not) and whether all other alarms are audible (or not).


S/N

SMA109S CIRCUIT BOARD(LEFT HAND CORNER)

OP

EN

1 2

3 4

5 6

7 8

HI TEMP CANCEL

FAN FAIL

TURN/DOOR

HIGH HUM

LOW TEMP

LOW HUM

MACH TYPE

ON

OFF

J1MODE 1 2 3

OFF ON

!


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FaN MOtOR OFF SWItCh (INCUBatORS)

Jumper setting J1 on the SMA109S circuit board is used to set the Fan Motor Off switch electrical compatibility with all other machines. The Fan Motor Off switch may be set in series (PT100 compatible) or parallel (E/M compatible). The default setting is E/M.


vOltaGe CheCk

With the control box lid open and the Main switch turned to Off (0), turn on the main power at the dis-tribution panel.

Check the voltage a cross the Main Power switch:

voltage

North America

220 volts between L1 and L3115 volts between L1 and L2 (Neutral)115 volts between L2 (Neutral) and L3

Other Locations

220 volts between L1 and L3 (Neutral)

Turn On the Main Power switch (1).

voltage

All Locations

115 volts between Transformer Neutral and FU5.

Turn the Main Switch Off (0).

Close and lock the lid.

J1 Setting for Fan Motor Off Switches

ONFan Motor Off switches in series - (PT100 compatible)

OFFFan Motor Off switches in parallel - (E/M compatible)

Warning: Jamesway recommends that only qualified electrical personnel set the initial parameters and do the electrical checks. Some circuits are energized with 220 Volts. They will cause serious shocks, injury or death if touched. Before setting the parameters, ensure that the Main Switch is turned to Off (0) and the power is locked out at the distribution panel.

The default setting is E/M.

ON

Main Power Switch

S/N

!

Location of Ground Bus, Transformer Neutral and Fuse, F5.

Warning: all the connections to the mains and protective earthing should be done by qualified personnel during installation.

Ground Bus

Transformer NeutralF5


MONItORING the 24-hOUR DRy RUN

Prior to use, test the other machine functions (fans and heaters) as usual. The machine should now be given a dry run and monitored for a 24-hour period. This will ensure proper functioning when eggs are loaded.

PRe-RUN

Open the control box. Check to ensure that the interior is clean and free of debris, (especially metal shavings) and all boards are properly seated.

Close the lid and key lock.

temperature and humidity Sensor Set-up

Fill the humidity water reservoir with distilled water. Using distilled water will prevent mineral build up.

Replace the stopper to reduce evaporation and con-tamination through the reservoir hole.

Install the wicking (PB4077) on the humidity probe following the directions in the side-box (Installing a Wick).

Ensure that the wick completely covers the probe.

Installing a Wick

Hold the top of the wicking with one hand and gently slide over the ex tended end of the probe.

Seat the wicking firmly around the probe.

Place the free end of the wicking in the res-ervoir, ensure it does not twist or bend. Any twists or bends will interrupt the flow of water through the wicking.

Warning: Always use wicking (PB4077) which is 12 inches (30 cm) in length. Incorrectly sized wicking may give inaccurate wet bulb readings.

Wick

Stopper

Reservoir


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temperature and humidity Settings

Adjust the temperature and humidity setpoints, using the side-box and the following machine specified set-points. (Refer to page 25 if necessary.)

Suggested temperature/humidity Setpoints

Incubators 99.0°F (37.22°C) 86.0°F (30.0°C)

Hatchers 98.5°F (36.94°C) 86.0°F (30.0°C)

For incubators, fully load the machine with empty racks, connect the air lines and turn alarm cables and install the curtains as usual. (Refer pages 59–62 of The Operations Manual for Multi-Stage – Chickens for detailed instructions.)

For hatchers, fully load the machine with empty dol-lies and baskets.

Dry Run

At this point, you are ready to start the machine and monitor a 24-hour dry run.

Turn the power to the On (1) position.

The temperature actual area on the display will show the software version, for example 4.03. The humidity actual area will show the machine type as selected on the SMA109S circuit board.

Machine type Readings

0 Incubator

1 Incubator without turn alarm

2 Chicken hatcher

3 Turkey hatcher

Ensure that the machine type selected is correct. If not, refer to Machine Type on page 11.

Turn on the fan switch located on the control box.

Use the checklist on the following page to visually monitor the machine.

temperature Setpoint

Use the following steps to set the temperature setpoint:

Press the button. The right hand digit in setpoint area will start to blink.

99.0

Enter the desired setpoint. For example, to enter 99.9, press 9 9 9.

Press the button to accept new the set-point, or press any other command button to cancel entry and leave the setpoint unchanged.

humidity Setpoint

Use the following steps to set the humidity setpoint:

Press the button. The right hand digit in the setpoint area will start to blink.

85.9

Enter the desired setpoint. For example, to enter 88.0, press 8 8 0.

Press the button to accept the new set-point, or press any other command button to cancel the entry and leave setpoint unchanged.

4.03 0

Actual Temperature area displaying software version 4.03; Actual Humidity area displaying machine type – in this case, zero, an incubator.


24-hour Dry Run—check the following several times throughout the period:

Incubator/hatcher Numbers 1 2 3 4 5 6 7

Temperature Setpoint Readout

Temperature Actual Readout

Humidity Setpoint Readout

Humidity Actual Readout

LEDs

Amperage on Main Heater

Amperage on Auxiliary Heater (incubator)

Damper Opening*

Spray Nozzles–position and pattern (incubator)

Egg Turning (incubator)**

Fans–off and on

Egg Turn Test (Incubators)

Press the Egg Turn button on the display. All incubator racks should turn each time this switch is depressed. Wait approximately five (5) minutes for the turn sequence to finish. If after five (5) minutes all racks have not completely turned, the Egg Turn alarm should sound, if the incubator is equipped with a turn alarm and the alarm is enabled. (See Alarm Set-up on page 12.) Also, the Common Alarm lamp should blink – rapidly if the Egg Turn alarm is audible and slowly if the Egg Turn alarm is inaudible. (See The Common Alarm Lamp on page 20.)

88.8

88.8

88.8

88.8

0 1 2 3 4

5 6 7 8 9

Location of the Egg Turn Button


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the DISPlay

The display of the PS501 Control System allows you to manage the machine environment by observing the status of actual parameters and making changes as necessary. Information outputs include:

• Actual Temperature and Humidity

• Temperature and Humidity setpoints

• Alarm status - active or inactive

• Heating, Cooling and Spray status – active or inactive

• Damper status - opening, closing, fully open or fully closed

• Turn status (incubators only) – racks turning, racks left or right and whether the turn valve solenoid is on or off, and

• The Common Alarm lamp – active or inactive.

Information inputs include:

• Changing the setpoints – both temperature and humidity

• Acknowledging alarms

• Testing the audible alarm

• Manually turning the eggs (incubators)

• Testing the spray function (hatchers)

• Calibrating temperature and humidity readout

• Setting the temperature units

• Programming each machine with a unique Hatch-com address

• Setting the Alarm Silence delay and

• Setting the Rack Turn interval (incubators).

The Controller Display, incubator shown. The Command Buttons, Function Button and Status Indicators, for the hatcher, differ slightly as shown to the right.

Actual Humidity

Actual Temperature

Humidity Setpoint

Temperature Setpoint

Numerical Keypad

Function Button

Command Buttons

FanSwitch

AlarmBypass

CommonAlarmLamp

PowerSwitch

DamperStatus

Heating/CoolingStatus

Alarm Status

Egg Turn Status(incubators)

88.8 88.8

88.888.8

0 1 2 3 4

5 6 7 8 9


BaSIC BUttON FUNCtION

Use the keypad (with numerals 0 to 9), Command buttons and the Function button to send information.

Simply press a command or function to initiate a change. Should you wish to cancel your entry, press any other command button. Your entry will then be cancelled and no changes will be made.

CONtROlS aND INDICatORS

The following is a brief description of the function and location of each of the controls. The indicators for the alarms and status are also known as LEDs or light emitting diodes. They will be referred to as LEDs in the following text.

Power Switch

The power switch was previously described on page 5.

Common alarm lamp

The Common Alarm lamp is a component of the total alarm system and is described in the Alarm section on page 20.

Fan Switch on the Control Box

The Fan switch on the bottom of the Control box is a grey toggle switch. To turn the fans on, pull the switch towards you.

With the switch in the On position the machine will run normally. When the fan switch is in the Off position the fans, heaters, spray valve, damper motor, egg turn air valve (incubator), blower (hatcher) and auxiliary damper (hatcher) are turned off.

In the Incubator

Turning off the fans will also turn off the egg turn solenoid valve. This will cause the racks to turn to the right. When the fans are turned back on, the racks will turn, if necessary, to restore previous turn state.

Incubator Keypad and Buttons

Hatcher Keypad and Buttons

Fan Switch

0 1 2 3 45 6 7 8 9

Keypad

Functions 1 - Temp. Calibration 2 - Hum. Calibration 3- Temp. Units 4 - Hatchcom 5 - Alarm Silence Delay

Commands Temp. Setpoint Hum. Setpoint Alarm Acknowledge Alarm Test Spray Test

0 1 2 3 45 6 7 8 9

Keypad

Functions 1 - Temp. Calibration 2 - Hum. Calibration 3- Temp. Units 4 - Hatchcom 5 - Alarm Silence Delay

Commands Temp. Setpoint Hum. Setpoint Alarm Acknowledge Alarm Test Egg Turn


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WaRNING

In the Incubator, there are two fan switches, one located on the controller and another located inside the cab near the entrance.

turn off both fan switches when working with the fans. Failure to do so could lead to serious injury.

WaRNING

The Fan switch, in the Off position, removes all power from inside of the incubator and hatcher. Failure to shut Off the Fan switch, during cleanup, will possibly expose the operator to a potentially lethal electric charge.

alarm Bypass Switch

The Alarm Bypass switch (the red toggle switch) is a component of the total alarm system and is described on page 21.

Fan Switch

When working with the incubator fans, ensure both fan switches are turned off.


alaRMS

When an alarm is active, it can be identified by three conditions:

1. A red blinking light (LED) adjacent to the alarm icon

2. The red Common Alarm lamp will blink and

3. The alarm will become audible, unless programmed to remain silent. See page 12.

leDs

Current and active alarms are identified by a red flashing light (LED or light emitting diode) which is situated adjacent to the alarm icon.

The LED will stop blinking and become solid when the alarm condition ends.

To clear the indicator light, press the Alarm Acknowledge (Silence) button.

Exception

When an active Egg Turn Failure alarm is acknowl-edged, the LED will clear immediately.

Common alarm lamp

Each alarm function is indicated by its own LED display. However, these LED’s are not visible from a distance; therefore, all alarm conditions will trigger the Common Alarm lamp to flash. This permits you to identify which machine, in a bank, has caused the alarm.

High Temp.

Low Temp.

Fan Failure

Maintenance

High Hum.

Low Hum.

Dry Wick

Egg Turn

High Temp.

Low Temp.

Fan Failure

Maintenance

High Hum.

Low Hum.

Dry Wick

Door open

Incubator Alarm Icons and LEDs

Hatcher Alarm Icons and LEDs

AlarmBypass

CommonAlarmLamp

Alarm Status

Incubator Control Box shown


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The Common Alarm lamp may show any of the fol-lowing conditions. The lamp will flash when an alarm is currently or was previously active. This flash will be rapid when the machine has an active alarm that is audible, and will be slow when the machine has an active alarm that is inaudible. The alarm light is continuously lit when the alarm bypass switch is activated.

The Common Alarm lamp can be cleared when no alarms are active by pressing the Alarm Acknowledge (Silence) button.

audible alarms

All alarms have a three-second delay before becom-ing audible. Any or all alarms can be programmed to remain silent. Refer to page 12 for initial Alarm set-up.

Note: On incubators, when turning off fans at entrance end of machine, there will be a five (5) minute delay before the alarm becomes audible. This allows enough time to load the machine without having to use the Alarm Bypass switch.

If there is an audible alarm, press the Alarm Acknowledge (Silence) button to temporarily silence alarms. However, if the alarm condition is not corrected within the allotted time, the Audible alarm will sound again. Refer to Alarm Acknowledge on page 26 for further information.

To set the allotted time before an alarm reactivates, refer to Alarm Silence Delay on page 28.

alarm Bypass

The Alarm Bypass switch on the bottom of the control box is a red toggle switch. To bypass an audible alarm, pull the switch towards you. The machine will now remain silent for all alarms and the Common Alarm lamp will remain continuously lit. Alarm Bypass allows you to transfer eggs, pull chicks, or clean the machine without a continuous audible alarm.

Common alarm lamp activity

Rapid Flash Active audible alarm

Slow Flash Active inaudible alarm or previous active alarm

Continuously Lit Alarm Bypass activated

Off No active or previous alarms

General alarm Sequence

leD audible alarm

Common alarm lamp

alarm Occurs

Flashes SoundsFlashes Rapidly

Press alarm acknowledge

Flashes SilentFlashes Slowly

alarm Condition Corrected

On SilentFlashes Slowly

Press alarm acknowledge once again

Off Silent Off


alaRM tyPeS

hIGh teMPeRatURe

This alarm activates when actual temperature exceeds the set point by 0.5°F (0.28°C) or more in an incubator, and 0.7°F (0.39°C) or more in a hatcher.

lOW teMPeRatURe

This alarm activates when actual temperature is 1.8°F (1.00°C) or more below the setpoint. As the temperature increases and returns to normal, the alarm will end when the actual temperature is within 1.3°F (0.72°C) of setpoint.

temperature alarms

High (Incubator)High (Hatcher)

Above setpoint by 0.5°F (0.28°C) Above setpoint by 0.7°F (0.39°C)

Low (Incubator and Hatcher)

Below setpoint by 1.8°F (1.00°C)

hIGh hUMIDIty

This alarm activates when actual humidity exceeds setpoint by 2.0°F (1.11°C) or more.

lOW hUMIDIty

This alarm activates when actual humidity drops 2.0°F (1.11°C) or more below setpoint. As the humidity in-creases and returns to normal, the alarm will end when actual humidity is within 1.5°F (0.83°C) of setpoint.

DRy WICk

This alarm activates when the actual humidity exceeds the setpoint by 9.0°F (5.0°C) or more.

humidity alarms

High Above setpoint by 2.0°F (1.11°C)

Low Below setpoint by 2.0°F (1.11°C)

Dry Wick Exceeds setpoint by 9.0°F (5.0°C)

FaN FaIlURe

This alarm activates on the incubator when any one of the Motor Off sail switches is not being pulled toward the fans (the fan motor may have prematurely stopped), or on the hatcher, when the current of one of the fan motors is below the minimum threshold.

MaINteNaNCe

This alarm activates in:

Hatchers when the Fan switch is turned off.

Incubators when the Fan switch on the control box or at the entrance end is turned off. When the entrance Fan switch is turned off, all alarms will be silenced for up to five (5) minutes or until fans are turned back on.

tURN FaIlURe

This alarm (incubators) activates if any one rack does not completed turning within five (5) minutes after the turn solenoid has changed state. This alarm can be cleared by pressing the Alarm Acknowledge button. If a rack does not complete a turn but then turns successfully in the other direction, the Egg Turn alarm will end.

NOte: When the turn solenoid is off, the racks must turn to right side and when solenoid is on, the racks must turn to left side, otherwise a Turn Failure alarm occurs on every turn.

DOOR OPeN

This alarm (hatchers) – under normal operating condi-tions, the alarm activates whenever one of the doors is opened.


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SySteM StatUS

The System Status indicators (LEDs) are located ad-jacent to the System Status icons. Each System Status LED will illuminate when its output function is in use.

In some instances, System Status indicators differ between incubators and hatchers. They are noted below.

MaIN heateR (INCUBATORS) OR heateR (HATCHERS)

When the temperature is 0.2°F (0.11°C) or more below setpoint, the incubator main heater or the hatcher heater turns on.

aUxIlIaRy heateR (INCUBATORS)

When the temperature is 0.4°F (0.22°C) or more below setpoint, the incubator auxiliary heater turns on.

COOlING (INCUBATORS)

When the temperature is 0.1°F (0.05°C) or more above setpoint, cooling solenoid turns on (if equipped).

PRIMaRy COOlING (CHICKEN HATCHERS)

When the temperature is 0.2°F (0.11°C) or more above setpoint, a signal is sent to the blower on the 2-Door Hatcher, or the one inch air solenoid on the PX Hatcher. (The primary cooling device for the 2-Door Hatcher is the blower while the primary cooling device for the PX Hatcher is the primary air valve and one inch solenoid.) Primary cooling is not used on turkey hatchers.

SeCONDaRy COOlING (HATCHERS)

When the temperature is 0.4°F (0.22°C) or more above setpoint, a signal is sent to the auxiliary blower on the 2-Door Hatcher, or the two inch air solenoid on the PX Hatcher. (The secondary cooling device for the 2-Door Hatcher is the auxiliary blower while the secondary cooling device for the PX Hatcher is the secondary air valve and two inch solenoid.)

SPRay

When the actual humidity is within 1.5°F (0.83°C) of setpoint (incubators) and within 0.5°F (0.27°C) of setpoint (hatchers), the spray turns on and will then cycle on and off. When the actual humidity is below these thresholds, the spray will remain continuously on.

DaMPeR ClOSe

When the temperature is 0.1°F (0.05°C) or more below setpoint (all incubators and chicken hatchers), or 0.2°F (0.11°C) below setpoint (turkey hatcher), the damper will close. The damper will stop closing when it has reached the fully closed position.

DaMPeR OPeN

When the temperature is 0.1°F (0.05°C) or more above setpoint the damper will open. The damper will stop opening when it has reached the fully open position.

DaMPeR FUlly ClOSeD

When the damper is now in the fully closed position. The damper will stop closing but is still allowed to open.

DaMPeR FUlly OPeN

When the damper is now in the fully open position. The damper will stop opening but is still allowed to close.

Each System Status LED will illuminate when its output function is in use - Primary Heat Status illustrated.


tURN valve (INCUBATORS)

The turn valve indicator shows whether the air solenoid on or off. Racks turn to right when solenoid is off, and turn left when solenoid is on.

all RaCkS leFt

The left turn indicator (incubators) lights up once all racks have turned to the left side. It will remain on as long as the egg trays are all in the left position. Should one rack fail to complete a turn sequence, this LED will remain off. After a period of five (5) minutes, the Turn Failure alarm will activate.

all RaCkS RIGht

The right turn indicator (incubators) lights up once all racks have turned to the right side. It will remain on as long as the egg trays are all in the right position. Should one rack fail to complete a turn sequence, this LED will remain off. After a period of five (5) minutes, the Turn Failure alarm will activate.

tURN IN PROGReSS

In the incubator, the Racks Turning indicator lights up while racks are in the process of turning or if any of the turn cables have not been hooked up. If one rack fails to turn properly, this LED will remain on. If the racks then successfully turn in the other direction, this LED will turn off.

Note: The alarm indicator lights for All Racks Left, All Racks Right and Turn in Progress will not illuminate if the Machine Type DIP switch is set for No Turn Alarm. Therefore, in incubators not equipped with a turn sensing system, set the DIP Switch setting for Egg Turn to the No Turn Alarm mode. The Egg Turn LEDs will then remain off. Refer to Alarm Set-up on page 12.

Racks turning left

Racks turning right


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COMMaND BUttONS

The PS501 Controller has five Command buttons. They are used to adjust the temperature setpoint, to adjust the humidity setpoint, acknowledge an alarm, test the audible alarm, manually turn the eggs in incubators and/or test the spray function in hatchers.

teMPeRatURe SetPOINt

Setpoints for temperature can be adjusted from the display. These setpoints will remain in effect until they are changed. Entering new setpoints will cause the ma-chine to alter its parameters as it uses these new targets.

If your machines are networked through Hatchcom, adjusting setpoints from the display may be disabled. Refer to Error Messages on this page.

adjusting the temperature Setpoint

1. Press the button. The right hand digit in setpoint area will start to blink.

2. Enter the desired setpoint. For example, to enter 98.8 press 9 8 8. The accepted range is 70.0 to 101.0°F (21.1 to 38.3°C).

3. Press the button to accept new the setpoint, or press any other command button to cancel entry and leave the setpoint unchanged.

Temperature adjustments can only be made within the following fixed range.

temperature adjustment Range

Fahrenheit 70.0–101.0°

Celsius 21.1–38.3°

hUMIDIty SetPOINt

Setpoints for humidity can be adjusted from the display. These setpoints will remain in effect until they are changed. Entering new setpoints will cause the machine to alter its parameters as it uses these new targets.

If your machines are networked through Hatchcom, adjusting setpoints from the display may be disabled. Refer to Error Messages on this page.

adjusting the humidity Setpoint

1. Press the button. The right hand digit in the setpoint area will start to blink.

2. Enter the desired setpoint. For example, to enter 86.0 press 8 6 0. The accepted range is 60.0 to 99.9°F (15.5 to 37.7°C).

3. Press the button to accept the new setpoint, or press any other command button to cancel the entry and leave setpoint unchanged.

Humidity adjustments can only be made within the following fixed range.

humidity adjustment Range

Fahrenheit 60.0–99.9°

Celsius 15.5–37.7°

eRROR MeSSaGeS

The following error messages may be displayed when adjusting either the temperature or humidity setpoint:

1. If the display shows “Loc” message, then Hatchcom has locked the setpoint and it cannot be changed at the machine.

2. If an invalid number is entered, the display will show “Err” message for several seconds before returning to the previous setpoint. No changes will be made.

3. For other error messages, refer to page 72.


alaRM aCkNOWleDGe

If there is an audible alarm, press the button to temporarily silence any alarm. Acknowledging the alarm will not cancel the alarm. (See Exceptions below.) The cause of the alarm must be corrected. Therefore, any of the following conditions may occur.

• If there is an active audible alarm, the Common Alarm lamp will blink rapidly.

• If there is an active inaudible alarm, the Common Alarm lamp will blink slowly.

• If there is no other active alarm, the Common Alarm lamp will extinguish.

• Any alarm which are no longer active but whose indicator (LED) is still lit, to show past activity, will be cleared.

• If an alarm is still active after the Silence Delay interval has past, the alarm relay will reactivate. This time delay can be programmed using the Alarm Silence Delay function. Refer to page 28.

• If a new alarm becomes active, the audible alarm, alarm indicator (LED) and Common Alarm lamp will reactivate immediately. (Refer to Common Alarm Lamp on page 20.)

exceptions

• The High Temperature alarm can only be silenced if the silence feature has been enabled with the DIP switch on SMA109S board. Refer to page 12.

• If there is an audible Egg Turn alarm, press the button to cancel the alarm.

alaRM teSt

Press the button to test whether the audible alarm system and display are working. As long as the button is pressed down, the audible alarm will ring and all digits and status lights will turn on. The audible alarm will not sound if the Alarm Bypass switch is on.

MaNUal eGG tURN (INCUBATORS)

Press the button to initiate a manual turn. The turn valve indicator light will change state, and the racks will turn to opposite direction.

An egg turn will occur each time this switch is de-pressed. Each turn sequence requires five (5) minutes to complete; therefore you must wait for five (5) minutes before calling for a second manual egg turn. When the Manual Egg Turn switch is pressed, the counter is reset. The next automatic egg turn will occur at the programmed number of minutes after the completion of the manual turn. The racks can only be turned when fans are on.

The time interval between each automatic egg turn can be programmed between 15 and 240 minutes. Refer to page 28.

SPRay teSt (HATCHERS)

Press the button to test the spray function. The spray will be active for as long as the button is pressed down. The spray will only activate if the fans are on.


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FUNCtION BUttON

The PS501 Controller is equipped with one Function button, which is used to calibrate the temperature readout, calibrate the humidity readout, set the tem-perature units, set the alarm silence delay and set the rack turn interval.

All operations must be completed within thirty (30) seconds, or else the display automatically changes back to the normal temperature and humidity display.

You may notice error messages such as Err or Loc appear as you attempt to key in your changes. Refer to Error Messages on page 72.

OR teMPeRatURe aND hUMIDIty CalIBRatION

The calibration function is used to adjust the sensor temperature if the Actual Temperature or Actual Humidity reading does not agree with the secondary measuring device such as a mercury thermometer or an electrotherm.

The temperature offset is the correction factor and is displayed in the Humidity Setpoint box. It is shown in degrees Fahrenheit or Celsius depending on the cur-rent temperature preference selection. The offset can be either positive or negative.

Machine Sensor Reading

+/- Offset = Corrected actual Reading

For detailed instructions on calibrating the sensor, refer to page 30.

teMPeRatURe UNItS

You may display the temperature units in degrees Fahrenheit or Celsius. The units you choose will also be used for humidity wet bulb readings.

Note: The machine is controlled in degrees Fahrenheit no matter which units you choose to display. If you select Celsius for your read-ings, you may notice that the machine appears not to be controlled to the correct setpoint. This is due to a slight conversion error as the machine’s actual reading (in Fahrenheit) is converted to Celsius.

Changing the temperature Readout Units

1. Press the button, the temperature setpoint area will show Fn.

2. Press the 3 button, the temperature setpoint area will show Fn3, and the humidity setpoint area blinks, showing the new units selection–°F or °C.

3. Press the button to accept the new units setting, or press any other command key to abort and leave the units setting unchanged.

hatChCOM aDDReSS

If the PS501 controller is networked to a Hatchcom system, each machine must be programmed with a unique address number. An incubator and hatcher pair is allowed to share the same address. The accepted range is 0 to 127.

Changing the address


2. Press the 4 button, the temperature setpoint area will show Fn4, and the humidity setpoint area blinks, showing the current Hatchcom address.

3. Enter the new network address, for example to enter 15 press 1 5.

4. Press the button to accept the new address, or


press any other command key to abort and leave address unchanged.

If an invalid number is entered, the display will show Err message for several seconds, and keep the current address.

alaRM SIleNCe Delay

When alarms are cancelled using the Silence but-ton, the silence delay setting determines the number of minutes all alarms will remain silent before returning to audible state. The accepted range is 1 to 99 minutes.

Changing the Delay time

1. Press button, the temperature setpoint area will show Fn.

2. Press the 5 button, the temperature setpoint area will show Fn5, and the humidity setpoint area blinks, showing the current delay.

3. Enter the new delay in minutes, for example to enter 5 minutes press 5. Press the button to accept the new delay, or press any other command key to abort and leave delay unchanged.

If an invalid number is entered, the display will show Err message for several seconds, and keep the current delay.

RaCk tURN INteRval

On incubators, the rack turn interval can be programmed from 15 to 240 minutes.

Programming the Rack turn Interval


2. Press the 6 button, the temperature setpoint area will show Fn6, and the humidity setpoint area blinks, showing the current turn interval.

3. Enter the new interval in minutes, for example to enter 60 minutes press 6 0.

4. Press button to accept the new turn interval, or press any other command key to abort and leave interval unchanged.

If an invalid number is entered, the display will show Err message for several seconds, and keep the current interval.


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The PS501 Multi-Stage control system requires routine maintenance. Many potential problems can be elimi-nated by following these simple procedures. Generally, system maintenance can be accomplished as part of your downtime during cleaning operations.

Warning: Jamesway recommends that only qualified electrical personnel service the ma-chines. Some circuits are energized with 220 volts. They will cause serious shocks, injury or death if touched. Before starting mainte-nance, ensure that the Main switch is turned to Off (0) and the power is locked out at the distribution panel.

CONtROl BOx

Inspect the hatcher control box once a week, and the incubator control box once a month.

PROCeDURe

Turn the fans off. Turn the Main switch off and ensure the power is locked out at the distribution panel.

Check for a build-up of chick down, dust or metal shavings. An excessive build-up of chick down will cause moisture to collect. Moisture may in turn cause the system to short circuit. Carefully vacuum the inside of the control box. It is not recommended that an air hose be used for this procedure.

Examine the boards, wiring, connections and relay contacts for obvious faults such as discolouration and burned or blackened areas. Pay special attention to terminals, connections and relay points.

Once maintenance is complete, and the interior of the control box is thoroughly dry, replace the control box lid. It is absolutely essential that this lid be in place and locked at all times.

Turn the power back on. Turn the fans back on.


The temperature and humidity sensor requires main-tenance as well as a more scrupulous cleaning once every three months.

Weekly PROCeDURe

Reservoir

Clean the water reservoir with detergent and a bottle brush to minimize the build-up of mineral deposits. If necessary, add water to the reservoir. Filling the reser-voir with water may also be required between weekly cleaning. (Jamesway recommends that only distilled water be used.)

Wick

Replace the wick every seven (7) days or more frequently, depending upon the mineral content of the water. Mineral deposits can build up in the wick, resulting in false readings.

to Install a Wick

Hold the top of the wicking with one hand. Gently slide over the extended end of the probe. Seat the wicking firmly around the probe. Place the free end of the wicking into the reservoir, Make sure it does not twist or bend. Any twists or bends will interrupt the flow of water through the wicking. The wicking should be 12 inches (30 cm) in length.

thRee MONth PROCeDURe

Probes

Hard water causes the probes to develop lime and cal-cium deposits. To clean the probes remove the probe baffle. Wash the probes in white vinegar or other mild acid solvent; rinse thoroughly with water. Failure to do so may result in probe deterioration. If water quality is poor, probes may require more frequent cleaning. Make sure that the temperature probe baffle is not out of position or damaged. The baffle should be on a horizontal plane to protect the probe from coming into direct contact with the spray or stray water particles.


CalIBRatION, GeNeRal CONSIDeRatIONS

environment

It is preferred that measurements of both dry and wet bulb temperature calibrations be accomplished during a period when the most stable environment exists. The most stable environment in a Multi-Stage incubator (Space Saver, Conventional Tunnel or Side Door) is 12 hours after setting. A chicken incubator should have six (6) fully loaded racks on each side. A turkey or duck incubator should have four (4) fully loaded racks on each side. The most stable environment in a Hatchcommander is 24 hours after complete setting. In a hatcher, both 2-Door and PX, it is 12 to 24 hours after transferring.

Always calibrate with the fans running and the tem-perature near the normal operating temperature.

equipment

To ensure that this procedure is carried out correctly, you should have:

1. A digital test thermometer of known accuracy with display resolution of 0.1°F (0.05°C), and

2. A probe-holding device as described below.

The holding device consists of two short sections of plastic tube taped side-by-side. The larger tube slides over the PS501 probe, while the instrument probe is inserted in the smaller one. Thus, the device effectively holds both sensing probes as close together as possible, without allowing them to touch. You may allow the shaft of the electrotherm to bend in order to obtain this desired closeness.

It is essential that the test thermometer be checked for accuracy regularly.

Procedure

With the two probes lined up and the hand-held ther-mometer read-out installed on the outside of the machine, the check can proceed.

Turn down the humidity setpoint to 80°F. Wait for about 10 minutes to allow both probes to settle and read accurately.

Calibrating the sensor - You may allow the shaft of the electrotherm (red) to bend in order to obtain this desired closeness to the probe.

Two short sections of plastic tubing taped side by side.


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TemperaTure CalibraTion


+/- Offset = Corrected actual reading

The temperature is calibrated in dry bulb. If the dis-play panel and the test thermometer readings differ by greater than 0.1°F (0.05°C), recalibration is required.

Calibrating the Temperature readout


2. Press 1 button, the temperature setpoint area will show Fn1, the humidity setpoint area will show the current offset from factory calibration, and the right hand digit in humidity actual area will start to blink.

3. Enter the reading from the electrotherm or calibra-tion thermometer, for example to enter 99.0 press 9 9 0.

4. Press the button to complete the calibration, or press any other command button to cancel calibration.

5. Wait 10 minutes, recheck and readjust, if necessary. When both readings are similar, the calibration procedure is complete.

If the controller displays Err message, then the new calibration exceeds the maximum allowed offset of 9.9°F (5.5°C) and the machine restores the previous calibration. This usually happens because of incorrect calibration procedure or a faulty temperature probe.

HumidiTy CalibraTion


+/- Offset = Corrected actual reading

The humidity can be calibrated either as a dry bulb or as a wet bulb.

For wet bulb, insert a separate wick on the electrotherm probe. Allow 10 minutes for the probe to stabilize and read accurately. If the display panel and the test ther-mometer readings differ by greater than 0.1°F (0.05°C), recalibration is required.

Calibrating the Humidity readout


2. Press 2 button, the temperature setpoint area will show Fn2, the humidity setpoint area will show the current offset from factory calibration, and the right hand digit in humidity actual area will start to blink.

3. Enter the reading from Electrotherm or calibration thermometer, for example to enter 86.2 press 8 6 2.

4. Press the button to complete the calibration, or press any other command button to cancel the calibration.

If the controller displays Err message, then the new calibration exceeds the maximum allowed offset of 9.9°F (5.5°C) and machine restores previous calibration. This usually happens because of incorrect calibration procedure or faulty humidity probe.

note: If temperature and humidity measure-ments show excessive differences, that is greater than 0.5°F (0.27°C), a further check, the following day may, be necessary. This allows the eggs more time to adapt to the new set points and the machine to stabilize to normal operational sequences.


alarm TesT

Press the button to test whether the audible alarm system and display are working. As long as the button is pressed down, the audible alarm will ring and all digits and status lights will turn on. The audible alarm will not sound if the Alarm Bypass switch is on.

note: If the audible alarm bell does not ring for any function where the alarm is enabled, check the battery, connections or alarm circuit. (Refer to page 12 for Alarm Set-up.)

Fan moTor oFF swiTCH TesT

Turn off the fans and unplug one motor. Then, turn the fans back on. The Fan Failure LED should light, the audible alarm should ring (if enabled) and the Common Alarm lamp should flash. Repeat the process for each motor.

Remember to switch off the fans each time before unplugging each motor.

Turn Failure TesT (InCubATOR)

Disconnect the turn cables at any location. The Turn Failure LED should light and the Common Alarm lamp should flash after five to seven (5–7) minutes. If selected, the audible alarm also should ring.

power oFF TesT

Turn off the power to the incubator. All of the LEDs on the display panel should go out, causing the audible alarm to ring.

THe display

Every three (3) months, during normal operations, check the display functions. This includes changing the temperature and humidity to simulate various machine conditions as well as testing all switches and other alarms.

HigH TemperaTure TesT

Drop the setpoint by one (1) degree. The High

Temperature LED should light and the Common Alarm lamp should flash, the damper should start open-ing, water should spray, and the audible alarm should ring (if enabled).

low TemperaTure TesT

Increase the temperature setpoint by two (2) degrees.

The Low Temperature LED should light and the Common Alarm lamp should flash,

HigH HumidiTy TesT

Drop the humidity setpoint by two (2) degrees or more.

The High Humidity LED should light and Common Alarm lamp should flash.

Alternatively, remove the wick from the probe. (Remember to replace the wick after testing.)

low HumidiTy TesT

Raise the humidity setpoint by two (2) degrees or more.

The Low Humidity LED should light and Common Alarm lamp should flash.

note: Remember to return the setpoints back to their original settings once the tests are completed.


Ro

uti

ne

Mai

nte

nan

ce

Maintenance Schedule Check

Warning: Jamesway recommends that only qualified electrical personnel service the ma-chines. Some circuits are energized with 220 volts. They will cause serious shocks, injury or death if touched. Before starting maintenance, ensure that the Main switch is turned to Off (0) and the power is locked out at the distribution panel.

Check all the items listed below as scheduled. Assess the condition. If the condition is as-sessed as unsatisfactory (not operating properly, excessive wear, dirt or any other potential problem) repair or replace, and/or clean prior to further use.

Items to be Checked Weekly Monthly every three

Months

Sensor

1. Reservoir - clean and fill as required2. Wick - replace3. Probes - clean

Calibration

1. Temperature Readout2. Humidity Readout

the Display

1. High Humidity Test2. Low Humidity Test3. High Temperature Test4. Low Temperature Test5. Alarm Test6. Fan Motor Off Switch Test7. Turn Failure Test (Incubator)8. Fan Motor Off and Door Open Test (Hatcher)

Control Box

1. Clean, vacuum as required2. Wire Condition3. Terminal Condition4. Relay Condition

HatcherHatcherHatcherHatcher

IncubatorIncubatorIncubatorIncubator

- indicates both incubators and hatchers


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The following pages contain a brief description of the operation of each component and lists all customer-replaceable parts.

The PS501 Control Box houses all the control system interconnections. The box contains a printed circuit board, which controls the system’s functions, as well as fuses, relays, power supply, a power transformer and the terminal strip to which all external wiring is connected.

INCUBatOR CONtROl BOx

Main Supply Switch—SW1 is a three pole switch supplying power to the controls when on.

Alarm Bypass Switch—SW2 is a double pole switch. A low voltage signal on first pole is active when in the closed (on) position, and alarm circuit on second pole is open or closed depending on whether alarm system is parallel or series.

Fan Switch—SW3 is a single pole switch. A low volt-age signal on first pole is active when in the closed (on) position.

FU1, FU2 and FU3—(for fan, main heater and auxiliary heater respectively) are 20 ampere fuses. They protect the contactors from a current overload, to prevent damage. When blown, locate the problem (e.g. electrical short), turn the Main Power switch to Off (0), repair the fault, replace the fuse and turn the power back on.

F U 4 A a n d B — ( t r a n s f o r m e r ) a r e 2 ampere fuses which protect the circuitry of the control system from a current overload. When blown, locate the problem (e.g. electrical short), turn the Main Power switch to Off (0), repair the fault, replace the fuse and turn the power back on.

FU5 through 11—(contactor coils, egg turn solenoid, spray solenoid, cooling solenoid, damper close, and damper open respectively) are 2 ampere fuses. The interior lights fuse is 5 amperes. When blown, locate the problem (e.g. electrical short), turn the Main Power switch to Off (0), repair the fault, replace the fuse and turn the power back on.

CR1, CR2 and CR3—are contactors that supply power to the fans, main heater and auxiliary heater.

Warning: The PS501 Multi-Stage Controller should only be serviced by qualified mainte-nance personnel. Do not attempt to service the controller while it is turned On. Some circuits are energized with 220 volts. They will cause serious shocks, injury or death if touched. Before servicing the control box, fans or heaters ensure that the Main switch is turned to Off (0) and the power is locked out at the distribution panel.

K1 through K7—are relays that control egg turn so-lenoid, spray solenoid, cooling, damper close, damper open, interior lights and alarm.

Transformer

BOaRDS

The current configuration includes the following boards:

SMA109S System Board—This board monitors all inputs and controls all output functions.

PT2324 Power Supply Module—The function of this module is to supply DC power to the system board, relays, and sensors.

PTA669S Communications Module—This optional module allows the controller to communicate with Hatchcom via fibre optics or Belden cable network.



1 ....... PB5940 ........ Disconnect Switch2 ....... PB5806 ........ Indicator Light Assembly ......... PT1094 ........ Lamp, 14 VDC3 ....... PB5807 ........ Transformer, 130 VA, 230/115V4 ....... PT2384 ........ Master Switch, 80 Amp.5 ....... PB5799 ........ Double Pole Fuse Block, (right to left), Fans, Main Heater, Aux. Heater ......... PB5800 ........ FU1-3, 20 Amp., Class CC6 ....... PT2285 ........ Fuse Block, Transformer ......... PT1073 ........ FU4A-4B, Fast Blow, 2 Amp.7 ....... PB5801 ........ Contactors, 4 Pole, 120 VAC Coil, CR1-3, (right to left) Fans, Main Heater, Aux. Heater8 ....... PT2285 ........ Fuse Block, (right to left) Contactor Coil, Egg Turn Solenoid, Spray Solenoid, Cooling Solenoid, Damper Close, Damper Open, Interior Lights ......... PT1073 ........ FU5-10, Fast Blow, 2 Amp. ......... PB5808 ........ FU11, Fast Blow, 5 Amp.

INCUBatOR CONtROl BOx

S/N

!

1

2

4

578910

11

12

13

17

14 15

16

3

6

9 ....... PB5802 ........ Relays, K1-7, SPDT, 12 VDC (right to left) Coil, Egg Turn Solenoid, Spray Solenoid, Cooling Solenoid, Damper Close, Damper Open, Interior Lights10 ..... PT1789 ........ Terminal Block, TB4,1-9 (right to left) Entrance Fan Switch, Fan Fail Switch, Light Switch, Left Turn Signal, Right Turn Signal, Damper Open Switch, Damper Closed Switch, Digital Common, Digital Common11 ..... PT2324 ........ Power Supply Module12 ..... PTA669S...... Communications Module (optional)13 ..... SMA109S ..... System Board14 ..... PT2028 ........ Fan Toggle Switch, SPST15 ..... PT1657 ........ Alarm Bypass Toggle Switch, DPDT16 ..... PT1141S ....... Platinum RTD Probes17 ..... PTA695 ........ Lid


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hatCheR CONtROl BOx

Main Supply Switch—SW1 is a three pole switch supplying power to the controls when on.

Alarm By-Pass Switch—SW2 is a double pole switch. A low voltage signal on first pole is active when in the closed (on) position, and alarm circuit on second pole is open or closed depending on whether alarm system is parallel or series

Fan Switch—SW3 is a single pole switch. A low volt-age signal on first pole is active when in the closed (on) position

FU1 and FU2—(for fan and heater respectively) are 10 ampere fuses. They protect the circuitry of the control system from a current overload, which may cause dam-age. When blown, locate the problem (e.g. electrical short), turn the Main Power switch to Off (0), repair the fault, replace the fuse and turn the power back on.

F U 4 A a n d B — ( t r a n s f o r m e r ) a r e 2 ampere fuses which protect the circuitry of the control system from a current overload. When blown, clear the faulty condition, turn the Main Power switch to Off (0), replace the fuse and turn the power back on.

FU5 through 10—(contactor coils, spray solenoid, auxiliary damper/2 inch solenoid, damper close, and damper open are 2 ampere fuses. 6A and 6B (blower/1 inch solenoid) fuses are 5 amperes. When blown, locate the problem (e.g. electrical short), turn the Main Power switch to Off (0), repair the fault, replace the fuse and turn the power back on.

Fan Contactor—(CR1) contactor supplying power to the fans.

Heater Contactor—(CR2) contactor supplying power to the heater.

K1 through K6—are relays that control blower/1 inch solenoid, spray solenoid, auxiliary damper/2 inch solenoid, damper close, and damper open.

Transformer

BOaRDS

The current configuration includes the following boards:

SMA109S Circuit Board—This board monitors all inputs and controls all output functions.

PT2324 Power Supply Module—The function of this module is to supply DC power to the system board, relays, and sensors.

PTA360S Current Sensing Module—This module monitors current draw in each of the two fan motors, sending a signal to the system board if the current is below the minimum threshold. It isolates the electron-ics from high voltage power.

PTA669S Communications Module—This optional module allows the controller to communicate with Hatchcom via fibre optics or Belden cable network.


S/N

!

1

2

4

5 78910

11

12

13

18

15

16

17

14

3

6

hatCheR CONtROl BOx


1 ....... PB5940 ........ Disconnect Switch2 ....... PB5806 ........ Indicator Light Assembly ......... PT1094 ........ Lamp, 14 VDC3 ....... FB5807 ........ Transformer, 130 VA, 230/115V4 ....... PT2383 ........ Master Switch, 40 Amp.5 ....... PB5799 ........ Double Pole (right to left) Fans, Heater ......... PB5810 ........ FU1-2, 10 Amp., Class CC6 ....... PT2285 ........ Fuse Block, Transformer ......... PT1073 ........ FU4A-4B Fast Blow, 2 Amp. 7 ....... PB5801 ........ Contactors, 4 Pole, 120 VAC Coil, CR1-2, (right to left) Fans, Heater8 ....... PT2285 ........ Fuse Block, (right to left) Contactor Coil, Blower (1 in. Solenoid), Spray Solenoid, Aux. Damper (2 in. Solenoid), Damper Close, Damper Open, ......... PT1073 ........ FU5, 7-10, Fast Blow, 2 Amp. ......... PB5808 ........ FU6B, 6A, Fast Blow, 5 Amp.

9 ....... PB5802 ........ Relays, K1-6, SPDT, 12 VDC (right to left) Blower 1 in. Solenoid, Spray Solenoid, Aux. Damper 2 in. Solenoid, Damper Close, Damper Open, Alarm10 ..... PT1789 ........ Terminal Block, TB4, 1-6 (right to left)Door Switches ,Fan Fail Signal, Damper Open Switch, Damper Closed Switch, Digital Common, Digital Common11 ..... PT2324 ........ Power Supply Module12 ..... PTA669S...... Communications Module (optional)13 ..... SMA109S ..... System Board14 ..... PTA360S ..... Current Sensing Module15 ..... PT2028 ........ Fan Toggle Switch, SPST16 ..... PT1657 ........ Alarm Bypass Toggle Switch, DPDT17 ..... PT1141S ....... Platinum RTD Probes18 ..... PTA696 ........ Lid


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1 ............................ Probe Mounting Baffle ......... MB16067 ..... Incubator ......... MB16163 ...... Hatcher2 ....... MB16261 ...... Probe Baffle3 ....... PT1141 ......... Probe Assembly4 ....... PB4529 ........ Liquid Tight Connector5 ....... PB4077 ........ Wick6 ....... AB5672 ........ Reservoir Assembly7 ....... MB15047 ...... Reservoir Holder8 ....... P2730 .......... Rubber Stopper9 ....... P6082 .......... #10 x 1/2 in. SS Self-drilling Screw

1

2

3

4

5

6

7 9

8

1

2

3

4

5

6

7 9

8

Incubator Sensor Hatcher Sensor


Hatcher Room

Incubator Room

Control Box

Mercury Free

Thermostat

aCCeSSORIeS

Green and red LEDs indicate the state of the circuit.

thermostat Junction BoxA mercury free thermostat and a mercury thermostat are available.In both cases, the thermo-stat should be placed in the vicinity of a temperature sensor.

Test switch verifies proper functioning of the LEDs and alarm relay. It does not test circuit operation.

Reset switch cancels the alarm.

Mercury thermostats are used as temperature sensing devices. Recommended ther-mostats: • for incubators - 101°F• for hatchers - 100°F.

BaCkUP alaRM

The Backup Alarm System is a secondary independent method of monitoring above normal operating tem-peratures due to overheating or failure of the regular alarm system.

Junction box is roof mounted


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aCCeSSORIeS

BatteRy OPeRateD CIRCUIt teSteR

PB3040

DIGItal theRMOMeteR

HA1070

INCUBatOR TURN TESTER

HA1145

velOMeteR aIR FlOW MeteR

HA1061

vOlt/aMPeRe PROBe

HA1133


Wir

ing

PO

WE

R S

UP

PLY

SW

1FU

120

AC

R1

CR

2C

R3

FU5 2AFU6 2AFU7 2AFU8 2AFU9 2A

FU10 2AFU11 5A

K1

K2

K3

K4

K5

K6

K7

TB4-1TB4-2TB4-3TB4-4TB4-5TB4-6TB4-7TB4-8TB4-9

MAIN SUPPLY SWITCH

FAN FUSES

MAIN HEATER FUSES

AUXILIARY HEATER FUSES

FAN CONTACTOR

MAIN HEATER CONTACTOR

AUXILIARY HEATER CONTACTOR

CONTACTOR COIL FUSEEGG TURN SOLENOID FUSESPRAY SOLENOID FUSECOOLING SOLENOID FUSEDAMPER CLOSE FUSEDAMPER OPEN FUSEINTERIOR LIGHTS FUSE

EGG TURN SOLENOID RELAY

SPRAY SOLENOID RELAY

COOLING SOLENOID RELAY

DAMPER CLOSE RELAY

DAMPER OPEN RELAY

INTERIOR LIGHTS RELAY

ALARM RELAY

ENTRANCE FAN SWITCHFAN FAIL SWITCHESLIGHT SWITCHLEFT TURN SIGNALRIGHT TURN SIGNALDAMPER OPEN SWITCHDAMPER CLOSED SWITCHDIGITAL COMMONDIGITAL COMMON

TRA

NS

FOR

MER

NEU

TRA

L

FU4B 2AFU4A 2ATRANSFORMER FUSES

TRA

NS

FOR

ME

R23

0 TO

115

VA

C13

0 V

A

13

5

NO

RTH

AM

ERIC

A(1

15VA

C P

HAS

E TO

NEU

TRAL

)1

- PH

AS

E 1

3 - N

EUTR

AL

5 - P

HA

SE

2

OTH

ER L

OC

ATI

ON

S(2

20VA

C P

HAS

E TO

NEU

TRAL

)1

- PH

AS

E5

- NEU

TRA

L

FU2

20A

FU3

20A

SW2

SW31

2

1 2 3

456

FAN SWITCH

ALARM BYPASS SWITCH

MO

UN

TED

ON

SID

E O

F B

OX

+12

+5+5CO

MC

OM

-12

4AA

C/L

AC

/N

INCUBatOR - CONtROl BOx layOUt


CR3AUXILIARY

HEAT

1 3 5 7

2 4 6 8

CR2MAINHEAT

1 3 5 7

2 4 6 8

CR1FANS220V

1 3 5 7

2 4 6 8

JUNCTIONBOX

(AB5480)

CEILINGOUTLET

ASSEMBLY

17 14 18 15 9 12 8 11

M M M M M M

AUXILIARYHEATER

MAINHEATER

GROUP 1FANS

GROUP 2FANS

BLAC

K 27

A

RED

54

BLAC

K 27

RED

55

BLAC

K 53

RED

41

BLAC

K 52

RED

41A

CR1FANS115V

1 3 5 7

2 4 6 8

BLAC

K 53

RED

41

BLAC

K 52

RED

41A

FOR 115V FANS ON NORTHAMERICAN SPLIT-PHASE

ONLY!

OR

42 6

1 3 5

SW1

INCUBatOR - FaNS aND heateRS


Wir

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42

3

K3

1 5

42

3

K1

1 5

42

3

K2

1 5

JUNCTIONBOX

(AB5480)1 2

JUNCTIONBOX

JUNCTIONBOX

NEUTRAL

WH

ITE

4

BLA

CK

5

OR

AN

GE

4A

BRO

WN

5A

SPRAYSOLENOID

115V

TURNING AIRSOLENOID

115V

COOLINGSOLENOID

115V(OPTIONAL)

1

2 3

DAM

PER

OVE

RR

IDE

SWIT

CH WH

ITE

BLA

CK

INCUBatOR - aIR aND WateR valveS


42

3

K6

1 5

3

4

JUNCTIONBOX

(AB5480)

115VCENTRE

115VEXIT

BLUE 51

RED 50

NEUTRAL

115VENTRANCE

42

3

K6

1 5

3

4

JUNCTIONBOX

(AB5480)

220VCENTRE

220VEXIT

BLUE 51

RED 50

NEUTRAL

220VENTRANCE

115 VAC LIGHT CONNECTION ON NORTHAMERICAN SPLIT-PHASE SUPPLY

DO NOT CONNECT LIGHTS TOTRANSFORMER NEUTRAL BAR!

220 VAC LIGHT CONNECTION

OR

42 6

1 3 5

SW1

FU320A

A B

1 3

2 4

INCUBatOR - INteRIOR lIGhtS


Wir

ing

TB4

8

8

TB4

7

7

TB4

6

6 42

3

K5

1 5

42

3

K4

1 5

M

NEUTRAL

RE

D

BLA

CK

WHITE

GREEN

OPEN CLOSE

WHITE

GREEN

BLACK

RED

BLACK

BROWN

RED

DAMPER DRIVE ASSEMBLY(PTA208)

BLA

CK

BR

OW

N

WH

ITE

12

31

2

3

DAMPERCLOSED

DAMPEROPEN

BROWN WHITE

BLA

CK

NOTE: If electro-mechanical damper box is used, additional wiresmust be installed, relay disconnected, and limit switches rewiredas per diagram. Only AB5484 three-wire motor is supported.

INCUBatOR - DaMPeR SySteM


TB4

9

9

TB4

9

9

WHITE BLACK

BLACK WHITE

JUNCTIONBOX

(AB5480)CEILINGOUTLET

ASSEMBLY

WHITE 29 WHITE 28

SET J1 "MODE"JUMPER ON

SMA109 TO "ON"FOR SERIES

CONNECTION

TB4

2

2

6 5

FAN OFF SWITCHES(PT-100 COMPATIBLE)

WHITE BLACK

BLACK WHITE

WHITE 29 WHITE 28

SET J1 "MODE"JUMPER ON

SMA109 TO "OFF"FOR PARALLELCONNECTION

TB4

2

2

6 5

FAN OFF SWITCHES(ELECTRO-MECHANICAL COMPATIBLE)

OR

INCUBatOR - MOtOR OFF SWItCheS


Wir

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TB4

1

1

TB4

3

3

TB4

9

9

FANLIGHTLIGHT

PTA193EXIT END

PTA418ENTRANCE END

WH

ITE

GR

EE

N

BLA

CK

BR

OW

N

BR

OW

N

RE

D

RE

D

NOTE: If not using a fan switch at entrance end, install ajumper wire between TB4-1 and TB4-9.

INCUBatOR - FaN aND lIGht SWItCheS


TB4

8

8

TB4

4

4

TB4

5

5

ENTRANCE END EXIT END

WH

ITE

16

BLAC

K 14

WHITE 15

BLACK 13

NOTE: If not connecting turn fail system, ensure that machine type switches onSMA109 board are set for incubator without turn alarm.

INCUBatOR - FaIl SaFe tURNING


Wir

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INCUBatOR - teMPeRatURe aND hUMIDIty SeNSOR, DIP SWItCh SettINGS

DIP SWITCH SETTINGS

- High temperature alarm can be silenced- High temperature alarm cannot be silenced1:

2: - Fan failure alarm is audible- Fan failure alarm is silent

3:

4:

5:

6:

7 8ON ON - IncubatorOFF ON - Incubator without turn alarmON OFF - Chicken hatcherOFF OFF - Turkey hatcher

ONOFF

- High humidity alarm is audible- High humidity alarm is silent- Low temperature alarm is audible- Low temperature alarm is silent- Low humidity alarm is audible- Low humidity alarm is silent

- Turn failure alarm is audible- Turn failure alarm is silent

ONOFFONOFFONOFFONOFFONOFF

J1: - Fan motor off switches in series (PT-100 compatible)- Fan motor off switches in parallel (E/M compatible)

ONOFF

SMA109 CIRCUIT BOARD

1 98765432 10

RE

D

WH

ITE

WH

ITE

TEM

PE

RA

TUR

E P

RO

BER

ED

WH

ITE

HU

MID

ITY

PR

OB

EW

HIT

E

TB1

1 2 3 4 5 6 7 8

OFF ON

J1

Machine type


42

3

K7

1 5

42

3

K7

1 5

4

5

6

BYPASSSWITCH

SW2

PREVIOUS MACHINE

NEXT MACHINE

SERIES ALARM SYSTEM(PT-100 compatible, alarm will soundwhen circuit is open)

4

5

6BYPASSSWITCH

SW2

PREVIOUS MACHINE

PARALLEL ALARM SYSTEM(Electro-Mechanical compatible, alarm willsound when wires touched together)

NOTE: Controller is factory wired for series alarm system! Relay andbypass switch must be rewired if parallel alarm system is used.

OR

NEXT MACHINE

INCUBatOR - alaRM CONNeCtIONS


Wir

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PO

WE

R S

UP

PLY

PTA3

60C

UR

REN

T S

EN

SE

MO

DU

LE

SW

1FU

110

AC

R1

CR

2

FU5 2AFU6B 5AFU6A 5AFU7 2AFU8 2AFU9 2A

FU10 2A

K1

K2

K3

K4

K5

K6

TB4-1TB4-2TB4-3TB4-4TB4-5TB4-6

MAIN SUPPLY SWITCH

FAN FUSES

HEATER FUSES

FAN CONTACTOR

HEATER CONTACTOR

CONTACTOR COIL FUSE

BLOWER / 1" SOLENOID FUSES

SPRAY SOLENOID FUSE

DAMPER CLOSE FUSEDAMPER OPEN FUSE

AUX DAMP / 2" SOLENOID FUSE

SPRAY SOLENOID RELAY

DAMPER CLOSE RELAY

DAMPER OPEN RELAY

ALARM RELAY

DOOR SWITCHESFAN FAIL SIGNALDAMPER OPEN SWITCHDAMPER CLOSED SWITCHDIGITAL COMMONDIGITAL COMMON

TRA

NS

FOR

MER

NEU

TRA

L

FU4B 2AFU4A 2ATRANSFORMER FUSES

SW2

SW31

2

1 2 3

456

FAN SWITCH

ALARM BYPASS SWITCH

TRA

NS

FOR

ME

R23

0 TO

115

VA

C13

0 V

A

13

5

NO

RTH

AM

ERIC

A(1

15VA

C P

HAS

E TO

NEU

TRAL

)1

- PH

AS

E 1

3 - N

EUTR

AL

5 - P

HA

SE

2

OTH

ER L

OC

ATI

ON

S(2

20VA

C P

HAS

E TO

NEU

TRAL

)1

- PH

AS

E5

- NEU

TRA

L

FU2

10A

BLOWER / 1" SOLENOID RELAY

AUX DAMP / 2" SOLENOID RELAY

MO

UN

TED

ON

SID

EO

FB

OX

+12

+5+5CO

MC

OM

-12

4AA

C/L

AC

/N

hatCheR - CONtROl BOx layOUt

Note: FU6A - Replace with 10A fuse (PB5823) when connecting two 115V blowers.


PTA360

CR2HEATER

220V

1 3 5 7

2 4 6 8

CR1FANS220V

1 3 5 7

2 4 6 8

M M

6 5 4 3 2 17

OR

AN

GE

BLU

E

WH

T/B

LK

RE

D

WH

ITE

BLA

CK

GR

EE

N

OR

AN

GE

BLU

E

WH

T/B

LK

RE

D

WH

ITE

BLA

CK

GR

EE

N

HEATER220V

FANS220V

WH

ITE

BR

OW

N

GR

N/Y

EL

GR

EY

K1-5 (+12VDC)

TB4-5 (Common)

TB4-2 (Fan Fail)

CR1FANS115V

1 3 5 7

2 4 6 8

OR

42 6

1 3 5

SW1

PTA360

4 3 2 1

WH

T/B

LK

RE

D

WH

ITE

BLA

CK

WH

ITE

FOR 115V FANS ON NORTHAMERICAN SPLIT-PHASE

ONLY!

hatCheR - FaNS aND heateR


Wir

ing

42

3

K1

1 5

42

3

K3

1 5

42

3

K1

1 5

42

3

K2

1 5

NEUTRAL

RE

D

SPRAYSOLENOID

115 VAC

AUXILIARYDAMPERMOTOR115 VAC

M

M

BLOWERMOTOR220 VAC

RE

D

1 INCH SOLENOID115 VAC

PX HATCHER

2 INCH SOLENOID115 VAC

PX HATCHER

WH

ITE

YELL

OW

FU6B

5A

WH

ITE

BLA

CK

WH

ITE

BLA

CK

WH

ITE

BLA

CK

GR

EE

N

GR

EE

N

GR

EE

N

FU6A

5A

* See note below for 115V PX solenoids

NOTE: When connecting 115 VACsolenoid valves on PX, wire onFU6A (top) must be moved fromFU4A to FU10 (top)

FU6B

5A

FU6A

5A

OR

TO FU4A TO FU10

NEUTRAL

M

BLOWERMOTOR115 VAC

SW1

1 3 5

2 4 6

BLA

CK

BLA

CK

NOTE: 115V blower option onNorth American split-phasesupply only! When connectingtwo 115V blowers replaceFU6A with 10A fuse (PB5823)

WHITE

hatCheR - aIR aND WateR valveS


TB4

5

5

TB4

4

4

TB4

3

3 42

3

K5

1 5

42

3

K4

1 5

NEUTRAL

RE

D

BLA

CK

WHITE

GREEN

OPEN CLOSE

BLA

CK

BR

OW

N

WH

ITE

M

WHITE

GREEN

BLACK

RED

BLACK

BROWN

RED

DAMPER DRIVE ASSEMBLY(PTA207)

NOTE: If electro-mechanical damper box is used, additional wiresmust be installed, relay disconnected, and limit switches rewiredas per diagram. Only AB5484 three-wire motor is supported.

12

31

2

3

DAMPERCLOSED

DAMPEROPEN

BROWN WHITE

BLA

CK

hatCheR - DaMPeR SySteM


Wir

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TB4

1

1

TB4

6

6

NCC

Common Wall Hatcher

WH

ITE

BLA

CK

NCC

TB4

1

1

TB4

6

6

NCC

WH

ITE

BLA

CK

NCC

NCC

PX Hatcher

hatCheR - DOOR SWItCheS


hatCheR - teMPeRatURe aND hUMIDIty SeNSOR, DIP SWItCh SettINGS

SMA109 CIRCUIT BOARD

1 98765432 10

RE

D

WH

ITE

WH

ITE

TEM

PE

RA

TUR

E P

RO

BER

ED

WH

ITE

HU

MID

ITY

PR

OB

EW

HIT

E

TB1

1 2 3 4 5 6 7 8

OFF ON

J1

DIP SWITCH SETTINGS

- High temperature alarm can be silenced- High temperature alarm cannot be silenced1:

2: - Fan failure alarm is audible- Fan failure alarm is silent

3:

4:

5:

6:

7 8ON ON - IncubatorOFF ON - Incubator without turn alarmON OFF - Chicken hatcherOFF OFF - Turkey hatcher

ONOFF

- High humidity alarm is audible- High humidity alarm is silent- Low temperature alarm is audible- Low temperature alarm is silent- Low humidity alarm is audible- Low humidity alarm is silent

- Door open alarm is audible- Door open alarm is silent

ONOFFONOFFONOFFONOFFONOFF

Machine type


Wir

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42

3

K6

1 5

PREVIOUS MACHINE

NEXT MACHINE

4

5

6BYPASSSWITCH

SW2

NOTE: Controller is factory wired for series alarm system! Relay andbypass switch must be rewired if parallel alarm system is used.

OR

SERIES ALARM SYSTEM(PT-100 compatible, alarm will soundwhen circuit is open)

42

3

K6

1 5

4

5

6

BYPASSSWITCH

SW2

PREVIOUS MACHINE

PARALLEL ALARM SYSTEM(Electro-Mechanical compatible, alarm willsound when wires touched together)

NEXT MACHINE

hatCheR - alaRM CONNeCtIONS


SMA109

115V

FU2A

20A

2 1

FU3A

20A

2 1

FU1A

20A

2 1

FU2B

20A

3 4

FU3B

20A

3 4

FU1B

20A

3 4

FU7

2A1 2

FU8

2A1 2

FU9

2A1 2

FU10

2A1 2

FU11

5A1 2

FU5

2A2 1

K14 3

115V

K24 3

115V

K34 3

115V

K44 3

K54 3

CR1A1 A2

CR2A1 A2

CR3A1 A2

PT2324 POWER SUPPLYOUTPUT: +5, +12, -12 VDC

MAIN HEATER

230V

FAN MOTOR BANK 1

230V

FAN MOTOR BANK 2

4AAC/L AC/N

208 - 230 VAC L2/NL1

5

6

SW1

21CR2

TURNING SOLENOID

SPRAY SOLENOID

COOLING SOLENOID

CLOSE

OPEN

230V

FAN CONTACTOR

MAIN HEAT CONTACTOR

AUX HEAT CONTACTOR

TB3-15 TB3-12

TB3-13

TB3-14

FU6

2A1 2

1

2

DAMPEROVERRIDE

SWITCH

AUXILIARY HEATER21

CR3

21CR1

65CR1

34CR2

34CR3

34CR1

78CR1

FU4A

2A1 2

FU4B

2A4 3

SW1

U20

U21

U22

DAMPERMOTOR

LIGHTSK64 3

230V

115V

TFR1

7,11

6

8,12

2 5

3

4

/ 115V

N

In North America only 115Vlights are connected to Neutralat terminal 4 with split-phase208 VAC connected across L1and L2 inputs (terminal 1 & 5)

Lights connected to 230 VAC

INCUBatOR - hIGh vOltaGe


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POWER SUPPLY

PTA669COMM

MODULE

SMA109

K515

K415

K715

X1X2

K615

K315

K215

K115

3 4

K7 ALARM RELAY

SAIL SWITCHES *

4 2

TB4-8

TB4-1 ENTRANCE FAN

FAN SWITCH

ALARM BYPASS

TB4-2

TB4-3

TB4-4

TB4-5

TB4-6

TB4-7

FAN FAILURE

LIGHT SWITCH

LEFT TURN

RIGHT TURN

DAMPER OPEN

DAMPER CLOSED

DGND

+12 VDC

EGG TURN

SPRAY

COOLING

LIGHTS

ALARM LIGHT

ALARM RELAY

CLOSE DAMPER

OPEN DAMPER

+5 VDC

DGND

+12 VDC

-12 VDC

TB4-9

TB3-5

TB3-6

TB3-7

TB3-8

TB3-20

TB3-21

TB3-22

TB3-23

TB3-24

TB3-25

TB3-26

TB3-27

TB3-9

TB3-6

TB3-1 (LED E8)

TB3-10

TB3-2 (LED E7)

TB3-3 (LED E6)

TB3-4 (LED E5)

TB3-16 (LED E4)

TB3-17 (LED E3)

TB3-18 (LED E2)

TB3-19 (LED E1)

TB1-1

TB1-2

TB1-3

TEMPERATUREWHITE

WHITE

RED

TB1-4

TB1-5

TB1-6

HUMIDITYWHITE

WHITE

RED

+12 VDC

ANALOG 1

DGND

ANALOG 2

+5 VDC

DGND

RXD

TXD

RTS

OUT

TB1-7

TB1-8

TB1-9

TB2-1

TB2-2

TB2-3

TB1-10

TB2-4

TB2-5

TB2-6

(SERIES ALARM SYSTEM)

12SW3

12SW2

6 5

Sail switches shown inseries connection withSMA109 MODE jumper setto ON.Set MODE jumper to OFFfor parallel connection.

*

INCUBatOR - lOW vOltaGe


SMA109

230V

FU2A

10A

2 1

FU1A

10A

2 1

FU2B

10A

3 4

FU1B

10A

3 4

FU7

2A1 2

FU8

2A1 2

FU9

2A1 2

FU10

2A1 2

FU5

2A2 1

K14 3

115V

K24 3

115V

K34 3

115V

K44 3

K54 3

CR1A1 A2

CR2A1 A2

PT2324 POWER SUPPLYOUTPUT: +5, +12, -12 VDC

HEATER

230V

FAN MOTORS

4AAC/L AC/N

208 - 230 VAC L2/NL1

5

6

SW1

21CR2

BLOWER

SPRAY SOLENOID

AUX DAMPER / 2" SOLENOID

CLOSE

OPEN

FAN CONTACTOR

HEATER CONTACTOR

TB3-15 TB3-12

TB3-13

TB3-14

FU6A

5A1 2

1

2

21CR1

34CR2

34CR1

SW1

U20

U21

U22

230V

PTA360

FU6B

5A3 4

115V

K14 3

1" SOLENOID 115 VACSOLENOID

FU4A

2A1 2

FU4B

2A3 4

FU6A

5A1 2

230 VAC BLOWER

NOTE: Primary cooling iseither connected as 230Vblower or 115V solenoid(115V blower not supported).

DAMPERMOTOR

J1

230V

115V

TFR1

7,11

6

8,12

2 5

hatCheR - hIGh vOltaGe


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POWER SUPPLY

PTA669COMM

MODULE

SMA109

K515

K415

K615

X1X2

K315

K215

K115

3 4

K6 ALARM RELAY

DOOR SWITCHES

4 2

TB4-5

FAN SWITCH

ALARM BYPASS

TB4-1

TB4-3

TB4-4

FAN FAILURE

DOOR OPEN

DAMPER CLOSED

DGND

+12 VDC

PRIMARY COOLING

SPRAY

SECONDARY COOLING

ALARM LIGHT

ALARM RELAY

CLOSE DAMPER

OPEN DAMPER

+5 VDC

DGND

+12 VDC

-12 VDC

TB4-6

TB3-5

TB3-6

TB3-7

TB3-8

TB3-20

TB3-21

TB3-22

TB3-23

TB3-25

TB3-26

TB3-27

TB3-9

TB3-6

TB3-1 (LED E8)

TB3-10

TB3-3 (LED E6)

TB3-18 (LED E2)

TB3-19 (LED E1)

TB1-1

TB1-2

TB1-3

TEMPERATUREWHITE

WHITE

RED

TB1-4

TB1-5

TB1-6

HUMIDITYWHITE

WHITE

RED

+12 VDC

ANALOG 1

DGND

ANALOG 2

+5 VDC

DGND

RXD

TXD

RTS

OUT

TB1-7

TB1-8

TB1-9

TB2-1

TB2-2

TB2-3

TB1-10

TB2-4

TB2-5

TB2-6(SERIES ALARM SYSTEM)

12SW3

12SW2

6 5

TB3-2 (LED E7)

TB4-2

PTA360BROWN

GRN/YELGRAY

DAMPER OPEN

PX ONLY

hatCheR - lOW vOltaGe


exteRNal aUDIBle alaRM

The External Audible alarm is wired for fail safe operation. When the system is not sounding an alarm K6 (incubator) or K7 (hatcher) is closed. This in turn energises the K2 NC contacts.

When an alarm occurs in any machine, K2 is de-energised and the alarm is activated. The alarm may be bypassed by activating Alarm Bypass (the red toggle switch) on the bottom of the control box.

INStallatION

Items K2, CR1, TB4, F4 are supplied in the FB5453 (12V) or FB5454 (24V) audible alarm pack. An alarm siren (PB4486) for 12 volt systems can be purchased from Jamesway, or the customer may choose to supply their own siren, bell or buzzer. The customer supplies the required wire (minimum 18/2 cable) to interconnect the PS501 control box, alarm box, stand-by battery, or other circuits external to the PS501 controls.


1 ....... PB4486 ........ 12 Volt HornF4 ..... PB4484 ........ Fast Blow FuseK2 ..... PB4481 ........ 12 Volt Relay, 5 AmperesCR1 .. PT1020 ........ Silicone Diode


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Network with Fibre Optics and Hatchcom PC as Master Poller

Installing a network in your hatchery will provide access from Hatchcom to any connected machine in the Hatchery. The Jamesway PS501 Controller System supports the Fibre Optic network or the Belden Cable network.

Before installing the network, install the PTA669S communication module by pushing the board onto connector TB2 of the SMA109 board. Install the screw supplied to fasten the module to the control box lid. See page 2 for a pictorial view.

Assign each machine a unique Hatchcom address as described on page 27 of this manual. Failure to give each machine a unique address will lead to commu-nication problems.

FIBRe OPtIC SySteM

The Fibre Optic System supports integration with Jamesway’s Multi-Stage machines.

Basic components are:

1. The Hatchcom PC which is the master poller.

2. The Fibre Optic hub which is a data distribution point on the network. Each hub has ten ports. Typically two are reserved for hub to hub communication. The remaining eight are used to connect incubators and hatchers.

3. The Fibre Optic cable which is the pathway for data on the network and connects Hatchcom, hubs, incubators, and hatchers. A specific fibre optic cable, available from Jamesway, is required for Jamesway machines.

FIBRe OPtIC CaBlING aND hUBS

Fibre optic cabling consists of a centre plastic core surrounded by a layer of protective material. This cable transmits light rather than electric signals and therefore is immune to electrical, lighting and moisture interference.

When installing, run the cable through conduit. It may be paired together with the high voltage wires. The maximum cable length between a machine and hub is

Fibre Optic Hub

Fibre Optic Cable

FIBRE OPTIC HUB POWER SUPPLY WIRING(ACDC or Condor POWER SUPPLY)

LINE VOLTAGE 120 220 230/240 CONNECT 1+2 2+3 2+3 TOGETHER 3+4 LINE

1+4 1+5 1+4CONNECTION

TERM . COLOUR 1 RED 2 YELLOW 3 BLUE 4 BLACK 5 ORANGE

PB 4839

Circuit Breaker

Power Supply

Hub closed

Hub

Master Poller

Cable

Machines


326 feet (100 m). The fibre optic cables are terminated with Jamesway duplex connectors at both ends (part number PT1888).

Fibre optic hubs will require a separate 115V/230V power circuit although several hubs can share the same circuit. Since fibre optic cables are not susceptible to electrical or moisture interference, the hub can be mounted on the wall, ceiling, hallway or the top of a machine.

GeNeRal INStallatION GUIDelINeS

The following are general guidelines for cable instal-lation:

• Always use more cable than you need. Leave plenty of slack.

• Fibre optic cables may run in the same conduit as the high voltage wires.

• When deciding the location of the hubs, pick a location that minimizes the amount of cable used.

• Hubs should be located where they can be easily serviced.

• Test every part of the network as you install it. If you do not, it may be difficult to isolate the problem later.

• Always run cable through a conduit for protection.

• Label both ends of each cable.

• Try to avoid tywrapping cables to the outside of a power conduit.

• Use cable ties (not tape) to keep cables together in the same location.

• Do not use staples to fasten data cables.

• If not all connectors are used inside a fibre optic hub, leave any extra connectors and polishing paper inside for hatchery expansion.

Duplex Connector (PT1888) Cable and Crimping Ring

When joining connectors and cable, cable orientation can be either/or.

Tab facing up

orText facing up on the left or right hand side of the two (2) strand cable


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POlIShING INStRUCtIONS

Polishing is an essential procedure for all cable con-nections. A connection is not ready for use until the following steps have been carried out. Long cables must be polished extra carefully to ensure reliable communication.

Step 1—The zip cord structure of the duplex cable permits easy separation of the channels. The channels should be separated approximately 2.0 inches (50 mm) back from the end to permit connecting and polishing. After cutting the cable to the desired length, strip off approximately 0.3 inches (7 mm) of the outer jacket with 16 gauge wire strippers. Excess webbing on du-plex cable may have to be trimmed to allow the duplex connector to slide over the cable. The separated duplex cable must be stripped to equal lengths on each cable. This allows easy and proper seating of the cable into the duplex connector.

Step 2—Place the crimp ring and the connector over the end of the cable; the fibre should protrude about 0.12 inches (3 mm) through the end of the connector. Carefully position the ring so that it is entirely on the connector with the rim of the crimp ring flush with the connector, leaving a small space between the crimp ring and the flange. Then, crimp the ring in place with the crimping tool.

Step 3—Any excess fibre protruding from the fibre end may be cut off. However, the trimmed fibre should extend at least 0.06 inches (1.5 mm) from the connect-ing end. Insert the connector fully into the polishing fixture with the connector end protruding from the bottom of the fixture.

Place the 600 grit abrasive paper on a flat smooth surface. Pressing down on the connector, polish the fibre and the connector using a figure eight pattern of strokes until the connector end is flush with the end of the polishing fixture. Wipe the connector and fixture with a clean cloth or tissue.

Step 4—Place the flush connector and the polishing fixture on the dull side of the 3 micron pink lapping film. Continue to polish the fibre and connector for approximately 25 strokes. The cable is now ready for use.

Placement of crimp ring

Polishing Equipment

Polish in a figure eight pattern

Note: The four dots, on the bottom of the polishing fixture, are wear indicators. Replace the polishing fixture when any dot is no longer visible.

Note: Use a clean cloth or tissue to wipe the end of the fibre optic cable. Do not wipe with your hands.

Duplex Crimping Ring

600 Grit Abrasive Paper

3 µm Lapping Film

Polishing Fixture

Polishing Paper

PolishingFixture


SPlICING INStRUCtIONS

Cables longer than 100 feet (30 m) should not be spliced because it will create a signal reduction that may cause a loss of communication. If a long cable needs to be repaired, install a new cable segment.

Step 1—Separate the duplex cable approximately 2.0 inches (50 mm) back from the end to permit connecting and polishing. Strip off approximately 0.30 inches (7 mm) of the outer jacket with 16 gauge wire strippers. Excess webbing on the duplex cable may have to be trimmed to allow the connectors to slide over the cable.

Step 2—Place the crimp ring and simplex connector over the end of the cable. The fibre should protrude about 0.12 inches (3 mm) through the end of the con-nector. Carefully position the ring so that it is entirely on the connector and then crimp the ring in place with the crimping tool.

Step 3—Any excess fibre protruding from the fibre end may be cut off. However, the trimmed fibre should extend at least 0.06 inches (1.5 mm) from the connecting end. Insert the connector fully into the polishing fixture with the connector end protruding from the bottom of the fixture. Place the 600 grit abrasive paper on a flat smooth surface. Pressing down on the connector, polish the fibre and the connector until the connector end is flush with the end of the polishing fixture. Wipe the connector and fixture with a clean cloth or tissue.

Step 4—Place the flush connector and the polishing fixture on the dull side of the 3 micron pink lapping film and continue to polish the fibre and connector for approximately 25 strokes. The fibre end should be flat, smooth and clean.

Simplex Connector and Cable

Step 1: Ensure correct measurements.

Step 2: Slide the cable into the crimp ring and simplex connector.

Step 3: The trimmed fibre should extend at least 0.06 inches (1.5 mm) from the connecting end.

Step 4: Polish in a figure eight pattern.

Splicing completed, insert simplex connectors into the bulkhead.

Note: Do not wipe the fibre ends with your fingers.

Simplex Blue Connector PT200

Blue text facing up on the left hand or right hand side of the two (2) stand cable

2.00 inches (50 mm)

0.30 inches (7 mm)

PT1969

Crimp Ring

Crimp Ring

0.06 inches (1.5 mm) minimum extension

Polishing Paper

PolishingFixture


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tROUBleShOOtING CaBle PeRFORMaNCe

If you are experiencing connection problems, check the following:

• Are all cable connections secure? Any connectors that are not plugged in may introduce ambient light into the system, which in turn disrupts com-munication.

• Were the connectors properly terminated and polished? If necessary, cut off ends and re-polish connectors. Long cables must be polished extra carefully to ensure reliable communication.

hOW tO CONNeCt tO hatChCOM

Once the PS501 controller is installed and connections to Hatchcom completed, it is necessary to configure the machine.

From the Hatchcom III Network menu choose PT100 > Configure.

Click Auto Configure to complete the process.


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From time to time, there will be an occasional mechanical breakdown or electrical failure. The fol-lowing is a logical approach to detecting and solving the problem.

Certain errors such as entering the wrong value or machine errors during start-up will be displayed in the temperature and humidity setpoint boxes. Refer to Error Messages in this chapter. For other problems such as a high temperature or egg turn failure, Jamesway sug-gests that you investigate for any physical cause before considering an electrical system failure. The Mechanical Checklist will assist you in this procedure. If the checklist does not help you solve your problem, proceed to Basic Troubleshooting and finally, the troubleshooting charts. These charts address problems at the Board level. If the problem persists, contact Jamesway.

Jamesway recommends that you use the following tools for investigating problems:

• A digital voltmeter, 4-1/2 digit (DVM)

• Ampere probe (clamp on style)

• Digital thermometer with at least two probes

• Turn tester

• Certified or mercury standard thermometer scaled to 0.1°F

• Insulated calibration tool, and

• Assorted hand tools, as needed.

The specific tools listed above are available through Jamesway.

Warning: The PS501 Multi-Stage Controller should only be serviced by qualified mainte-nance personnel. Do not attempt to service the controller while it is turned On. Some circuits are energized with 220 volts. They will cause serious shocks, injury or death if touched. Before servicing the control box, fans or heaters ensure that the Main switch is turned to Off (0) and the power is locked out at the distribution panel.


Error MEssagEs

The display may show several different error messages in the Temperature and Humidity Setpoint boxes. They are:

Err—This indicates that a value, which is outside the accepted range, was entered. Re-enter an acceptable value. Refer to Temperature Setpoint and Humidity Setpoint on page 25 for allowed values.

Loc—The setpoint has been locked. This feature is only available when connected to a Hatchcom network and can only be accessed from the main Hatchcom terminal. In case of a Hatchcom communication failure, cycle the power to enable setpoint changes.

dEF—On start up, there was a checksum error in the nonvolatile memory for setpoints, temperature units, alarm silence delay, rack turn interval, and Hatchcom address settings. When this error occurs, the controller restores these parameters to their factory default set-tings. Press any button to clear the message from the display. The machine will now operate normally using the factory default settings. If you choose any settings other than the factory defaults, you must reprogram the machine. If the problem persists on next power cycle, then SMA109S Circuit board is faulty and needs to be replaced.

Factory Defaults

Temperature Units

Fahrenheit Refer to page 27.

Alarm SilenceDelay

3 seconds Refer to page 28.

Rack Turn Interval

60 minutes Refer to page 28.

Hatchcom Address Setting

Incubator (0) Refer to page 27.

OCh—On start up, there was a checksum error in nonvolatile memory for field calibration offsets. The controller restores all calibration offsets to zero. Press any button to clear the message from display. You must immediately check the temperature and humid-ity calibration and recalibrate, if necessary. Refer to page 30. If the problem persists on next power cycle, then SMA109S Circuit board is faulty and needs to be replaced.

CCh—On start up, there was a checksum error in nonvolatile memory for factory calibration settings. The SMA109S Circuit board is faulty and needs to be replaced. Press any button to clear the message from display, but the actual readings will show 0.0 and the normal machine operation will be suspended.

FLt—A fault was detected on start up. Report the fault code shown to Jamesway for further assistance. If the fault code occurred during a software upgrade, press the Fn button to re-attempt the upgrade, or remove the upgrade chip before the next power up.

ErS—This message indicates flash is being erased during a software upgrade

PrG—This message indicates flash is being programmed during a software upgrade

0.0—If either the temperature or the humidity probe is faulty, the corresponding actual display will read 0.0. Replace the faulty probe as required.

MEchanical chEcklist

Before opening the control box an inspection of the appropriate mechanical operations, as listed below, may uncover the source of a problem.

hEat

Display indicates high temperature, check the following:

1. Actual unit temperature.

2. Plenum temperature (optimum 80°F or 27°C).

3. Intake and exhaust drive for proper operation (should be opening or open).

4. Improper fogging (spray activity)

5. Space between incubator racks; ensure racks are pushed together and butt up against each other.

Display indicates low temperature, check the follow-ing:

1. Actual unit temperature.

2. Heat rods for actual operation.


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3. Intake and exhaust drive (should be closed or closing).

4. Air leakage around doors.

5. Excessive fogging.

6. Plenum temperature (optimum 80°F or 27°C).

7. Plenum humidity (optimum 50% to 60% RH).

huMiDity

Display indicates humidity high, check the following:

1. Actual humidity.

2. Wick and water reservoir.

3. Magnetic valve. If not seating, check if arrow is opposite to flow.

4. Water pans overflowing.

5. Very high humidity in incoming air.

Display indicates humidity low, check the following:

1. Actual humidity.

2. Nozzles for proper fogging (spray activity).

3. Magnetic valve if no spray.

4. Water pressure (55 psi or 379 kPa minimum).

5. Intake and exhaust drives for proper operation.

Egg turn

Individual rack in a row fails to turn 45 degrees, check the following:

1. Defective cylinder.

2. Pinched air line.

3. Mechanical binding of linkages.

All racks in unit turned but LED (Turn Failure) flashing check the following:

1. Each turn switch for continuity.

Basic trouBlEshooting

Jamesway recommends that before proceeding to Visual Inspection, all possible sources of error, as listed in the Mechanical Checklist, were inspected.

Visual inspEction

First, turn Off the power. Unlock and open the lid of the control box being aware of the potential shock hazard that exists here.

1. Visually inspect for loose connections e.g. loose screws on terminal blocks, relays, etc.

Check voltage and current

Voltage

AllLocations

115 volts between Transformer Neutral and FU5.

2. Check that fuses are not blown.

3. Check for burnt foil pattern on boards.

Finally, refer Troubleshooting Charts located in this section. Please note (below) the position of the relay contacts when a relay is on or off. This will aid in your inspection.

If a particular board is expected to be defective, power to the unit must be turned Off, before the board is removed and replaced with a spare board.

If the problem persists a Jamesway technician should be contacted.

ON OFF

When a relay is ON, the middle and the bottom connec-tions make contact. When a relay is OFF, there is a space between the middle and the bottom connections.


tROUBleShOOtING ChaRtS

The following Troubleshooting charts outline a course of action to be followed beyond the mechanical opera-tions and into the electronic board level of the PS501 Multi-Stage Control System. By following the flow of arrows you can, by process of elimination, solve most problems.

hIGh teMPeRatURe alaRM

1. Check actual temperature with a known good thermometer. If calibration is needed, it should be done now. Refer to Calibration on page 30 and 31.

2. Check for correct damper operation (opening or fully open).

3. Check rack position, gaskets and space between racks. Make sure all gaskets are in good repair.

4. Make sure temperature probe remains dry. If it gets wet, it will cause the heaters to activate. When the probe is dry, the heat will cause the High Tempera-ture alarm to ring.

5. If more than one machine has this problem, then the plenum temperature should be checked.

After the above is checked, examine the control system.

Check both heaters with Amp probe, clamping around one wire at end of heating element, not around element.

In Incubator:

Reading is approximately 12 to 14 amps when the machine is calling for heat, and zero amps when no heat is required.

In hatcher:

Reading is approximately 7 to 8 amps when machine is calling for heat, and zero amps when no heat is required.

This indicates that heater circuit is operat-ing properly.

If current measurement is greater than zero when machine is not calling for heat, check if CR2 and CR3 contactors are pulled in.

If contactor is not pulled in, there is a problem with wiring to heater ele-ments.

If contactor is pulled in, measure AC coil voltage across terminals A1 and A2.

If voltage is absent, replace contactor.

If voltage is present, replace SMA109S circuit board.

If heating system is working normally, check damper system.


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lOW teMPeRatURe alaRM

1. Check for actual temperature with a known good thermometer. If calibration is needed, it should be done now. See Calibration on page 30 and 31.

2. Check for correct damper operation (closing or fully closed).

3. Check gaskets and thresholds. If either one is missing, it will allow cold air to come into the machine.

4. Make sure that your temperature probe remains dry and the baffle is in the correct position.


Check both heaters with Amp probe, clamping around one wire at end of heating element, not around element.

In Incubator:

Reading is approximately 12 to 14 amps when the machine is calling for heat, and zero amps when no heat is required.

In hatcher:

Reading is approximately 7 to 8 amps when machine is calling for heat, and zero amps when no heat is required.

This indicates that heater circuit is operat-ing properly.

If current measurement is zero when machine is calling for heat, check if CR2 and CR3 contactors are pulled in.

If contactor is pulled in, check for AC voltage on contactor across terminals 2 and 4.

If contactor is not pulled in, meas-ure AC coil voltage across terminals A1 and A2.

If voltage is present, replace contactor.

If voltage is absent, measure AC volt-age from TB3-15 to NEUTRAL bar.

If heating system is working normally, check damper system.

If voltage is present, check heater wiring and replace element.

If no voltage is present, check FU2 and FU3 fuses.

If voltage is absent, replace FU5 fuse.

If voltage is present, replace SMA109S board.


hIGh hUMIDIty aND/OR DRy WICk

1. Check the wick. Make sure it is in good condition and has not dried out. Also check water reservoir. It should be at least 3/4 filled with water.

2. Check actual humidity with a known good ther-mometer. If calibration is needed, it should be done now. See Calibration on page 30 and 31. Make sure water pans are draining correctly.


Check whether the spray nozzles are spraying water.

If the nozzles are not spraying, look for other sources of water entering the cabi-net, for example from plenum area or water on hatcher room floors seeping under thresholds.

If nozzles are spraying, visually check whether K2 relay is in ON position.

If relay is OFF, meas-ure AC voltage from K2-3 to NEUTRAL bar.

If relay is ON, measure DC coil volt-age across K2 relay terminals 1 and 5.

If voltage is absent, check spray solenoid wiring and replace solenoid.

If voltage is present, check wiring and replace relay K2.

If voltage is greater than 1VDC, replace SMA109S circuit board.

If voltage is absent, replace relay K2.


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lOW hUMIDIty

1. Check for actual humidity with a known good thermometer. If calibration is needed, it should be done now. See Calibration on page 30 and 31.

2. Check gaskets and thresholds. If either is missing, it will allow air to get into your machines and more humid air to escape.

3. Make sure that your spray nozzles are not clogged or badly worn.

4. Check water pressure at nozzle. It should be a minimum of 55 psi (379 k Pa).


Check whether the spray nozzles are spraying water.

If the nozzles are spraying, this indi-cates that the spray circuitry is operating correctly.

If nozzles are not spraying, visually check whether K2 relay is in ON position.

If relay is ON, meas-ure AC voltage from K2-3 to NEUTRAL bar.

If relay is OFF, measure DC coil volt-age across K2 relay terminals 1 and 5.

If voltage is present, check spray solenoid wir-ing and replace solenoid.

If voltage is absent, check FU7 fuse.

If voltage is approximately 12 VDC, replace relay.

If voltage is absent, replace SMA109S circuit board.


FaN FaIlURe alaRM (INCUBatOR)

1. Check for proper blade rotation and make sure that the sail switches are drawn in.

No fans are run-ning:

Make sure panel and entrance fan switches on (verify LED E7 and E8 on).

Check if CR1 contactor is pulled in.

How many fans are running?

One bank not work-ing:

Check wiring on output side of CR1 contactor up to the ceiling outlet assembly.

One fan not work-ing:

Let motor cool down and then restart. If this does not correct the problem, replace the motor.

All fans are running:

Check MODE jumper J1 on SMA109S circuit board.

If contactor is pulled in, check FU1 fuses.

If contactor is not pulled in, measure AC coil voltage across terminals A1 and A2.

If MODE is set to OFF, sail switches must be in parallel.

Is LED E6 on?

If MODE is set to ON, sail switches must be in series.

Is LED E6 on?

If voltage is present, replace CR1 contactor.

If voltage is absent, measure AC volt-age from TB3-15 to NEUTRAL bar.

leD e6 is OFF:

Replace SMA109S board.

leD e6 is ON:

Check wiring and re-place sail switch.

leD e6 is ON:

Replace SMA109S circuit board.

leD e6 is OFF:

Check wiring and replace sail switch.

If voltage is absent, replace FU5 fuse.

If voltage is present, replace the SMA109S circuit board.


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DaMPeR NOt OPeNING OR ClOSING

1. Check the operation of micro switches in the damper drive box.

2. Make sure the damper motor and drive assembly are in working condition and not jammed.

3. Make sure that the damper is not obstructed.

4. Make sure that slide rod couplings and set screws are secure.


What is the damper output status on dis-play?

Damper is set to close. Visually check that relay K4 is ON and relay K5 is OFF.

Damper is set to open. Visually check that relay K5 is ON and relay K4 is OFF.

If relays are not correct, measure DC coil voltages across terminals 1 and 5.

K5 voltage should be zero and K4 should be 12 VDC.

If voltages are cor-rect, replace faulty relay, else replace SMA109S circuit board.

If relays are correct, measure AC output voltage across relay terminal 3 and NEUTRAL bar.

Reading should be zero when relay off, or approximately 115 VAC when on.

If relays are correct, measure AC output voltage across relay terminal 3 and NEUTRAL bar.

Reading should be zero when relay off, or approximately 115 VAC when on.

If relays are not correct, measure DC coil voltages across terminals 1 and 5.

K4 voltage should be zero and K5 should be 12 VDC.

If voltages are cor-rect, replace faulty relay, else replace SMA109S circuit board.

If voltages are correct, replace damper motor.

If voltages are incorrect, replace FU9 fuse.

If voltages are correct, replace damper motor.

If voltages are incorrect, replace FU9 fuse.


DOOR alaRM (hatCheR)

1. Make sure that the door is not ajar.

2. Check all door switches, check for any lose wire. This is the correct time to replace a bad switch.


What is the state of LED E7 on the SMA109S circuit board?

LED E7 is ON.

One of the door switches is not working or not hooked up correctly.

If voltage is absent, replace SMA109S cir-cuit board.

If voltage is present, check wiring and replace door switches.

LED E7 is OFF.

Measure DC voltage between TB4-1 and TB4-6.


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eGG tURN FaIlURe (INCUBatOR)

1. Make sure that all of your turning cords are con-nected.

2. Make sure that there is no split or pinched air lines and all racks are fully turned.

3. When no turn cords are used, make sure that ma-chine type switches are set to Incubator without turn alarm. See page 11 for more information.

4. When turn solenoid is off, racks must turn to right, with turn solenoid on, racks must turn to left.


How many of the racks are turning?

All racks turn completely:

Check status of LED E3 and E4 on SMA109 board.

With turn valve indicator ON, racks should be turned left, LED E3 should be OFF, and LED E4 should be ON.

Some of the racks turn:

Connect two racks at a time (one on each side of aisle) with air hoses until you dis-cover the rack which will not turn. Check for defective air cylinder, air line, or binding racks.

None of the racks turn:

With turn valve indicator ON, visually check that relay K1 is in ON position.

If relay is ON, measure AC volt-age from K1-3 to NEUTRAL bar.

If relay is OFF, measure DC coil voltage across K1 relay terminals 1 and 5.

If voltage is present, check turn solenoid wir-ing and replace solenoid.

If voltage is absent, check FU6 fuse.

If voltage is approximately 12 VDC, replace relay.


If LED E3 and E4 lights are correct, replace SMA109S circuit board.

If LED E3 and E4 lights are reversed, check that air lines are hooked up cor-rectly. Verify installation instructions for proper wiring of left and right turn signals.

If LED E3 and E4 lights are both off, check continuity of each rack with an HA1145 rack tester.


BlOWeR DOeS NOt WORk

1. Make sure blower is hooked up for correct voltage. See Wiring page 53 for more information.

2. Make sure machine type is set to Chicken Hatcher. See page 11 for more information.


With display showing primary cooling ON, visually check whether relay K1 is in ON position.

If relay is ON, measure AC voltage from K1-3 to NEUTRAL bar.

If relay is OFF, measure DC coil voltage across K1 relay terminals 1 and 5.

If voltage is present, check wiring and replace blower.

If voltage is absent, check FU6 fuses.

If voltage is approximately 12 VDC, replace K1 relay.


ON OFF

When a relay is ON, the middle and the bottom connec-tions make contact. When a relay is OFF, there is a space between the middle and the bottom connections.


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eRRatIC DISPlay PaNel ReaDINGS

1. Check for sources of electrical interference. Reroute probe wires if necessary. Possible noise sources are:

Alarm system.

Faulty fan motor.

Other electrical equipment on same circuit.

Eliminate any sources of electrical inter-ference as listed above.

Verify power supply voltages on SMA109S circuit board:

TB3-5 to TB3-6: +5 VDC +/- 0.1

TB3-7 to TB3-6: +12 VDC +/- 0.6

TB3-8 to TB3-6: -12 VDC +/- 0.6

Check temperature probe connections.

See installation instructions for hookup.

Replace probes if necessary.

If problem persists, replace SMA109S

circuit board.


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Alarm Bypass Switch—A switch used to bypass the ex-ternal audible alarm while the machine is serviced.

Calibration—A procedure to adjust a derived meas-urement to match the actual measurement of a unit or quantity. Adjustment is required to ensure that the temperature and humidity readouts on the display panel are the same as the actual temperature and humidity inside the incubator or hatcher.

Checksum Error—An error in the sum derived from the bits of a segment of computer data that is calculated before and after transmission or storage. This summa-tion check ensures that the data is free from errors or tampering.

Circuit Breaker—A mechanical device used to inter-rupt current flow (amps) if it is greater than the rating of the circuit breaker. Circuit breakers protect the electrical parts of the control system from a current overload which could cause damage.

Control Box—An enclosure that houses circuit boards, power devices, and connection points for external wiring of devices. It is also the location of the circuit breakers.

DIP Switches—Miniature slide or rocker switches used to select different control options. They are located on the SMA109S system board inside the control box.

Display—A unit that visually shows the status and operating conditions of a machine. It is used, by the operator, to receive information and send instructions to the control system.

Dry Wick—This alarm is found on the display panel. It is an indication of a too dry environment in the incubator and/or hatcher. The sensor for a dry wick condition is the humidity probe. A Dry Wick condition is usually caused by water reservoir or spray nozzle problems.

Egg Turn Solenoid Valve—An electro-mechanical device used to control air flow to the air cylinder in the incubator racks to turn the eggs. In the Jamesway incubators, eggs can be turned 45 degrees at prescribed times.

Flash Memory—The microprocessor contains flash memory which stores the control software. Flash memory allows for simple software updates if necessary.

Hatchcom Address—A unique number assigned to a unit which allows networking of the units. In the case of the PS501, they are set by using command function Fn4. Addresses allow Hatchcom to interpret which PS501 Controller is in turn controlling which hatchers or incubator. An address setting from 0 to 127 may be used.

HA1070 Digital Thermometer—an instrument used to measure temperature.

HA1128 Digital Voltmeter—an instrument used to measure voltage.

HA1133 Ampere Probe—an instrument used to measure AC current.

HA1145 Turn Tester—Test equipment used to check that the incubator racks turn correctly both to the left and to the right.

LED (Light Emitting Diode)—An electronic device that emits light when a current is passed through it. In the case of the PS501 Controller, these are the system status and alarm lights on the display panel.

Non-volatile Memory—Computer memory that can retain stored information even when not powered. Non-volatile memory is typically used for the task of secondary storage, or long-term persistent storage.

Plenum Chamber—The air space surrounding the incubators in which temperature and humidity are controlled.

Program Error—A condition that arises when a set point is outside the allowable range.

Set Point—The desired parameters (in this case the hu-midity and temperature) at which the PS500 Controller will regulate the incubator and/or hatcher in order to achieve optimum environment.

user's manual - jamesway · 2019. 8. 9. · jamesway incubator company inc. 30 high ridge...

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