work instruction templet - jamesway

Jamesway Incubator Company

Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit

Instruction #: JIC-INSTP24-00004

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Operation Instruction Title: ECU Harness Retrofit – 24VDC

Revision Date: 02-04-2019 Revised By: V. Frail

Revision No. A Approved By: S. Ditner

Page 1 of 12

Step (picture) Step (Instructions) Step (Tools

Required)

Step (Safety &

PPE)

Motor Retrofit

Note: this is only required if the motors have a techno connector (black and teal) in place.

For motors shipped with a grey liquid tight and typically black cable, skip ahead to step 6.

JIC-INSTP24-00004 Step 1

Remove the motor lid.

Throughout:

Safety Shoes

Safety Glasses

Hearing protection

as required

Additional

equipment as

required by the site


Cut the existing cable just outside the

techno connector.

Unscrew the connector from the motor

housing.

Keep the rubber grommet for later use.


Unscrew the motor wires from the

connector.

Remove and discard all connector pieces.


Remove the motor wires out through the

side of the ECU frame.

Keep both the snap grommets and the

venturi rubber grommets for later use.


Repeat steps 1-4 for the remaining 3

motors.




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Page 2 of 12


Required)

Step (Safety &

PPE)

Harness Removal

Note: Some ECUs may have been shipped without the harness in place. If this is the case, skip ahead to step 10.


Disconnect the ECU power supplies from

the console, and pull the cables back

through to the ECU.


Remove each junction box from the ECU

frame and discard.

Note: For electric heat models, junction

boxes will be located on both sides of the

ECU frame.


Cut the cables and remove them.

Also remove the push-in cable ties.

This may all be discarded.


Remove the connector mounting clamps

and discard.

The ECU frame should now be free of the

previous ECU harness.




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Page 3 of 12


Required)

Step (Safety &

PPE)

ECU Frame Modification

Note: This series of steps is required for all ECUs shipped without the new harness in place.


Carefully tape or place the templates to

the ECU frame, depending on which

templates are required.

Mark the center each hole with a punch.

Refer to the ECU models at the end of this

document for specific placement

information.


Drill holes as required by the templates.

Note: For the cable hole using the 13/16”

drill bit, use drill bits in steps to increase

the hole size and use minimal pressure on

the drill. Alternatively, use a step drill and

drill from both sides to adequately widen

the hole.

Hole Drill Bit

Junction box 10-32 combination

drill/tap

Humidity nozzle

bracket

¼ x 20 combination

drill/tap

Plug base (on ECU

support)

#7 drill bit

Cable hole(s) in side

frame base for

plug(s)

13/16” bit or step

drill

Grounding wire hole 10-32 combination

drill/tap


Deburr the ECU frame cable hole(s).

Note: For electric heat ECUs, this hole

should be drilled, and deburred on both

sides of the frame.




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Page 4 of 12


Required)

Step (Safety &

PPE)


Mount the junction box(es) in place on the

ECU frames using:

P6147 Machine Screw

PT1195 washer

P6226 spacer

The washer should be located on top of

the junction box.

Note: Electric heat junction boxes will be

mounted directly to the frame. Apply a

small amount of silicone to the rear of the

box before applying.


Note: If the motor has been shipped with

the correct cable in place, skip this step.

Put the motor cables through the holes in

the top of the ECU frame (fitted with snap

grommets) and through the rubber

bushing in the venturi.

Note: You may need to use a small

amount of soap to pass the cable through

the rubber bushing.


Connect the grounding cable from the last

junction box on each ECU to the hole

drilled from the template using a PT1191

screw and P6409 washer.

Spacer

Motor cables




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Page 5 of 12


Required)

Step (Safety &

PPE)


Use the push-in cable ties (1000692) to

secure the cables inside the ECU channel.


Insert the P6309 grommet in the prepared

hole(s) and pass the console connection

cable(s) through.

Note: For electric heat ECUs, this hole

should be drilled, deburred and fitted with

a grommet on both sides of the frame.


Insert the cable into the plug(s) for the

ECU.

Tighten the liquid tight.

Note: Ensure the cable insulation is visible

inside the box before tightening the liquid

tight.


The black wires have numbers printed on

them. Insert those numbers into the

appropriate slots in the plug. Connect the

ground wire to the screw on the end of

the plug.

Plug Wir

e 1

Term

inat

ion

Wir

e 2

Term

inat

ion

Wir

e 3

Term

inat

ion

Base & Plug:

SD & DD Front

Fan

1 2 3

Base & Plug:

SD & DD Front

Electric Heat

1 2 3

Base & Plug:

DD Rear Fan 4 5 6

Base & Plug:

DD Rear

Electric Heat

4 5 6

Ground wire

Wires numbered




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Page 6 of 12


Required)

Step (Safety &

PPE)


Note: Each plug and base has a different

orientation.

Plugs – Male Pins

Plug – SD & DD Front Fan

Plug – SD & DD Front Electric Heat

Plug – DD Rear Fan

Plug – DD Rear Electric Heat

Insert the plug into the housing and

tighten the screws. Ensure the orientation

is correct for the plug you are connecting.

Bases – Female Pins

Base – SD & DD FRONT Fan

Base – SD & DD FRONT Electric Heat

Base – DD REAR Fan

Plug – DD REAR Electric Heat




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Page 7 of 12


Required)

Step (Safety &

PPE)


Ensure the liquid tight is fully tightened.

Connecting the Electric Heaters


Insert the three leads from the electric

heater through the 3-holed grommets and

through the liquid tights on the junction

boxes.


Strip the tips of each wire approximately

8-10 mm.

Either wire may be 1 or 2; the heaters are

non-polarized.


Connect the black wires from the heating

electrode to the provided terminal strip.


Strip and add a ferrule to the ground wire.




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Page 8 of 12


Required)

Step (Safety &

PPE)


Connect the ground wires to the grounds

on the terminal blocks.

For reference, the junction box should be

wired as follows:

Terminal Wire

1 H1-1

2 H3-2

3 -

4 H2-1

5 H1-2

6 -

7 H3-1

8 H2-2


Tighten the liquid tights on the junction

box.


Install the lid on the junction box using the

supplied screws and tighten fully.

Use zip ties to neatly secure the wires

together.


Follow Steps 18-21 to connect the electric

plug.




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Page 9 of 12


Required)

Step (Safety &

PPE)

ECU Support Leg Modifications (Mounting the Plug Receptacles)


If not already completed, mount the

templates on the ECU support legs as

indicated, and drill the holes with the #7

drill bit.


Mount the receptacles on the legs using:

PT1234 Screws

1001286 Nuts

Note: The fan power receptacles should be on the right leg of the ECU support, and the electric heat receptacles on the left leg.

Console Modification


Mount the templates on the console and

transfer the hole locations with a punch.


Use a step drill bit to drill the holes out to

20 mm (13/16”).

Deburr the holes.


Insert the snap-in liquid tight, and tighten

the nut to fully locate it.

Note: The liquid tight may be the 1000677

or the 1002213. Both are acceptable for

this installation.




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Page 10 of 12


Required)

Step (Safety &

PPE)


Pass the console cables through the liquid

tight into the consoles.


Pass the cables through the liquid tights in

the bottom of the control housing.


Wire Color

& Number

Wire to

location

Receptacle

– Front ECU

Fan

Black (1)

147D VFD1 – U2

Red (2)

0148D VFD1 – V2

White (3)

149D VFD1 – W2

Green VFD1 -

Ground

Receptacle

– Rear ECU

Fan

Black (1)

0169A VFD2 – U2

Red (2)

0170A VFD2 – V2

White (3)

0171A VFD2 – W2

Green VFD2 -

Ground

Receptacle

– Front

ECU

Electric

Heat

Black (1)

0106B CB2-2 (2T1)

Red (2)

0107B CB2-4 (4T2)

White (3)

0108B CB2-6 (6T3)

Green Ground

busbar

Receptacle

– Rear ECU

Electric

Heat

Black (1)

0112A CB3-2 (2T1)

Red (2)

0113A CB3-4 (4T2)

White (3)

0114A CB3-6 (6T3)

Green Ground

busbar

Wire the cables as indicated on the wires,

to the ground and VFD for the fans, and to

the contactors for electric heat.

Note: Cables may either have different

colors or be black and labelled 1-2-3. Label

numbers are shown in brackets




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Page 11 of 12


Required)

Step (Safety &

PPE)


Remove the previously used liquid tights

from the console and replace with the

plugs. Ensure they are fully tightened.

Motor Re-Wiring

Insert the liquid tight into the motor, with a rubber washer against the motor and a metal washer on top. Insert the motor cable through the liquid tight into the motor, ensuring a small amount of the outer jacket shows inside the motor.


Trim the existing ferrules off the terminals. Strip each wire and connect to the matching wire on the motor cable using PB3678 terminals.




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Page 12 of 12


Required)

Step (Safety &

PPE)


Zip ties the wires back towards the

outside of the motor housing.

Ensure that the wires are securely

fastened away from the motor shaft.


Close the lid of the motor securely, adjust

the motor lead length and secure to the

fan guard using 1 zip tie.


Repeat for the remaining 3 motors.

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