MS Routine Monitoring and Maintenance

Transcription

1 MS Routine Monitoring and Maintenance PT100 and EM controls incubators and hatchers ventilation checklists specifications for ventilation and fan blade spacing

2 The Jamesway multi-stage incubator system is an efficient material handling and incubation system, producing strong, healthy, active chicks. Nevertheless, in order to obtain optimal production, management should establish and implement regular monitoring and regular maintenance schedules. Maximum benefit will not be obtained if one is implemented without the other. Adapt a monitoring and maintenance program tailored to your specific needs using this manual and Note: The monitoring and maintenance information contained with this chapter is the basic requirement for good performance. To further enhance performance, refer to Chapter 7, Optimizing Performance on page 143. the manual for your control system. BASIC GUIDELINES FOR MONITORING EQUIPMENT Jamesway recommends that personnel from maintenance take and record the following readings using a checklist and the time schedule as suggested below. Assess each item. Is it operating satisfactorily? Unsatisfactory would include variance between set points and actual readings, equipment not functioning or showing excessive wear, dirt build up or any other potential problem. All problems should be investigated and corrected prior to further use. Check Space Saver Intake Duct after each set. to prepare and follow a checklist suited to your hatchery. TEMPERATURE AND HUMIDITY READINGS Record the temperature and humidity readings. Note any variance between actual and set points. Make necessary corrections. MONITORING INCUBATORS It is important to assess the general machine condition as well as the temperature and humidity at prescribed times. This time schedule varies. General machine condition which includes such items as the position of the eggs rack, baffles, curtains, etc. should be checked immediately after every set. Spray nozzles and audible alarms should be checked daily. Also, temperature and humidity should be read, recorded and compared on a twice daily basis. Check the egg turn mechanism every three hours. A table for monitoring incubators, including items and time schedules, is on page 103. Use this table, SPACE SAVER INTAKE DUCT Mixing of incoming fresh air with re-circulating air is important to proper machine function. To ensure that fresh air is correctly mixed, an intake duct has been installed on the centre post between the entrance end doors. The duct includes an upper section attached to the roof and a lower section attached to the centre post. The lower portion is easily removable for cleaning purposes. Since the duct is not permanently attached and protrudes into the entrance end slightly, care must be taken when loading eggs. Check the intake duct

3 after each set. Make sure it is in the proper position and if required, reposition. The correct spacing is 5/8 inches (15.5 mm) and the duct should be parallel with the centre post on both sides. MONITORING HATCHERS It is equally important to monitor hatchers. Assess the general machine condition as well as the temperature and humidity at prescribed times. This time schedule varies. General machine condition which includes such items as fan blades, heat elements, etc. should be checked prior to transfer. Spray nozzles should be checked daily. Also, temperature and humidity should be read, recorded and compared on a twice daily basis. A table for monitoring hatchers, including items and time schedules, is on page 104. Use this table, to prepare and follow a checklist suited to your hatchery. TEMPERATURE AND HUMIDITY Record the temperature and humidity readings. Note any variance between actual and set points. Make necessary corrections. MONITORING VENTILATION EQUIPMENT ENVIRONMENTAL CONDITIONS Install magnehelic gauges to assist you in monitoring the incubator and hatcher environments. Mount them in a stationary position in the vicinity of the pressure controllers, making sure they are level. Install a tee on the tube running from the exterior to the controller low pressure port. Connect a tube from the low pressure port of the magnehelic gauge to the tee. Both the controller and magnehelic should have similar readings. Establish a program to monitor and record their readings, as well as the temperature and humidity readings of each room. Readings should be recorded twice daily and twice nightly. With this type of program, you should be able to pick up any malfunction of the ventilation equipment. A table for monitoring the ventilation system is on page 105. Jamesway recommends all hatcheries maintain a Note: In some instances the pressure controller may be mounted externally to the room. In these cases the monitoring instrument must be connected to the low pressure (external reference) and room high pressure tubes. A tee on both lines is required. Monitoring Schedule for Incubators All of the items mentioned below should be checked, as scheduled. Refer to page 101 for additional notes. Actual readings should be recorded and compared with the optimum. All other items should be assessed as to their operating condition either satisfactory or unsatisfactory. Unsatisfactory would include not operating properly, excessive wear, dirt or any potential problem. Items, not in satisfactory condition, should be repaired or replaced, and/or cleaned prior to further use. A) Temperature Calibration 1. Display reading F or C 2. Check reading F or C 3. Set point F or C B) Humidity Calibration 1. Display reading RH FWB or CWB 2. Check reading RH FWB or CWB 3. Set point RH FWB or CWB C) General Machine 1. Position of egg rack against the venturi 2. Rubber baffle condition 3. Curtain condition 4. Curtain position 5. Heat rods 6. Fan rotation 7. Motor off switches 8. Doors seal properly 9. Doors latch properly 10. Door gasket condition 11. Threshold gasket condition 12. Threshold position 13. Space Saver intake duct position 14. Egg turning mechanism 15. Audible alarms 16. Spray nozzles, no excessive dripping 17. Spray nozzle pattern 60 Immediately After Every Set Every 3 Hours After Set Twice Daily Daily

4 Monitoring Schedule for Hatchers All of the items mentioned below should be checked, as scheduled. Refer to page 102 for additional notes. Actual readings should be recorded and compared with the optimum. All other items should be assessed as to their operating condition either satisfactory or unsatisfactory. Unsatisfactory would include not operating properly, excessive wear, dirt or any potential problem. Items, not in satisfactory condition, should be repaired or replaced, and/or cleaned prior to further use. A) Temperature Calibration 1. Display reading F or C 2. Check reading F or C 3. Set point F or C B) Humidity Calibration 1. Display reading RH FWB or CWB 2. Check reading RH FWB or CWB 3. Set point RH FWB or CWB C) General Machine 1. Fan blade condition 2. Fan blade spacing 3. Fan rotation 5. Heat rings 6. Hatcher rack track condition 7. Hatcher rack track position 8. Doors seal properly 9. Doors latch properly 10. Door gasket condition 11. Threshold gasket condition 12. Threshold position 13. Spray nozzles, no excessive dripping 14. Spray nozzle pattern 60 Pre-Transfer Twice Daily Daily Monitoring Schedule for Ventilation All of the items mentioned below should be checked, as scheduled. Refer to page 102 for additional notes. Actual readings should be recorded and compared with the optimum. Investigate any inconsistent readings. Record in each plenum A) Magnehelic Gauge 1. Display reading in.w.g or Pa 2. Check reading in.w.g or Pa 3. Optimum pressure in.w.g or Pa B) Temperature 1. Display reading F or C 2. Check reading F or C 3. Optimum temperature F or C C) Humidity 1. Display reading RH FWB or CWB 2. Check reading RH FWB or CWB 3. Optimum humidity RH FWB or CWB Twice Daily and Twice Nightly

5 catalogue of the ventilation equipment, as well as the components of that equipment, including motor size, pulley and belt size, etc. It is also important to become familiar with the operations of the ventilation equipment. From this information, you can establish both a spare parts list and a routine preventive maintenance program. ROUTINE MAINTENANCE FOR INCUBATOR PT100 CONTROLS Refer to the checklist on page 115. WEEKLY Reservoir Clean the water reservoir with detergent and a bottle brush to minimize the build-up of mineral deposits. If necessary, add distilled water to the reservoir. (Filling the reservoir with distilled water may also be required between weekly cleaning.) 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 in. (30 cm) in length. 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 - placement of the electro-therm (HA1071) next to the PT100 sensor Calibration Check the accuracy of the temperature and readings. It is important that the electro-therm (HA1071) be positioned correctly next to the PT100 probe. Allow the shaft of the electro-therm to bend. Fit the tip of the shaft into the plastic sleeve and as close to the PT100 sensor as possible. They should not touch. For the testing procedure and calibration refer to The PT100SMT Controls and System Manual, page 85. Display Panel Check the PT100 display panel during normal incubator operation. Dial the temperature or humidity thumbwheel switches up or down to simulate various machine conditions. Dial the humidity thumbwheel up 2 degrees or more. The low humidity LED should flash. Note: Remember to turn the thumbwheel switches back to their original set points once the check is completed. High Temperature Dial the temperature thumbwheel down 1 degree. The high temperature LED and alarm should flash, the damper should start opening, water should spray, and the audible alarm should ring. Alternatively, press and hold the Test button on the display panel until a 1 appears. This will activate the audible alarm. Low Temperature Dial the temperature thumbwheel switch up 2 degrees. The low temperature LED should flash. Fan Motor Off Switch Turn off the fans and unplug one motor. Then, turn the fans back on. The fan failure LED should flash and the audible alarm should ring. Repeat the process, switching off the fans each time before each motor is unplugged. This checks each fan motor off switch for correct function. Turn Failure Disconnect the turn cables at any location. The turn failure LED should flash after 5 to 7 minutes. If selected, the audible alarm also should ring. Power Off Turn off the power to the incubator. All of the LEDs on the display panel should go out, causing the au- Note: On the PT100SMT display, all digits and LEDs will light up when the Reset button is pushed. On the PT100 display, all digits and most of the LEDs will light up. In the System Status, only the Damper Open and Damper Closed LEDs will light. The heat, spray and egg turn LEDs will not light up unless they were already lit before the Reset button was pushed. dible alarm to ring. Alarms Warning: The PT100 controller should only be serviced by qualified maintenance personnel. Do not attempt to service the controller while it is turned on. Some circuits are energized with 220 or 380 volts ac. They will cause serious shocks, injury or death if touched. Before servicing the control box, ensure that CB1, CB2 and CB3 are turned off. If the audible alarm bell does not ring for high temperature, fan off or power off, check the battery, battery connections or alarm circuit. Display Panel LEDs Press the Reset button for less than 3 seconds to turn on LEDs. (See Note.) If a digit segment or LED does not work, replace the display panel. EVERY THREE MONTHS Probes Hard water causes the probes to develop lime and calcium deposits. To clean the probes remove the probe baffle. Wash the probes in white vinegar or High Humidity Dial the humidity thumbwheel down 2 degrees or more. The high humidity LED and alarm lamp should flash. Alternatively, remove the wick from the probe; remember to replace the wick after testing. Low Humidity PT100 Display Panel

6 Control Box Turn the fans off. Turn the power off - CB1, CB2 and CB3. Refer to page 56. Open the control box, and examine the PT100 boards Incubator Thermostat Board and wiring, wiring connections and relay contacts for obvious faults such as discoloured wiring, and burned or blackened areas. Pay special attention to terminals, connections and relay points. Vacuum the interior if dust, chick down or metal shavings have accumulated. After vacuuming, ensure plug connections are snug. In older models, check that the boards are firmly seated. Turn the power back on. Turn the fans back on. ROUTINE MAINTENANCE FOR INCUBATOR ELECTRO-MECHANICAL CONTROLS Refer to the checklist on page 116. WEEKLY Reservoir Clean the water reservoir with detergent and a bottle brush to minimize the build-up of mineral deposits. If necessary, add distilled water to the reservoir. 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. Warning: The thermostat contacts are electrically live. Therefore, open the control panel and disconnect the power to the thermostats before removing. Failure to do so could result in injury. 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 in. (30 cm) in length. EVERY THREE MONTHS Thermostats Hard water will cause lime deposits to form on the thermostats. Wash the thermostats in white vinegar or other mild solvent. Rinse thoroughly in cold water. The clips also should be cleaned with a fine emery cloth to remove mineral deposits. If water quality Warning: In order to test the following circuits, switch the power on. Jamesway recommends that you use an insulated jumper wire with insulated alligator clips or probes to perform the following checks. Make sure all personnel are clear of the fans before switching on. is poor, thermostats may require more frequent cleaning. Information Panel Check for burned wires, defective relays and burned out bulbs. Control Box The best time to check the control box is after complete clean-out. Wires, Connections and Bulbs Turn the power off. Open the control box, the cover interlock switch will disconnect the power to fans. Check the wiring, wiring connections and relay contacts for obvious faults, such as discoloured wiring, or burned or blackened areas. Pay special attention to relays points, connections and terminals. Check for burnt out bulbs. Close the Control Box Cover, the fans will switch on. High Temperature Circuit Using the insulated jumper wire, connect one clip to bottom contact of one of the thermostats. Attach the other clip to the top contact of the High Temperature thermostat (middle thermostat). The high temperature light on the Information Panel comes on, the audible alarm will sound, and the damper starts opening. If the heat and auxiliary heat pilot light are on they will turn off during this test. Remove jumper wire from both contacts when test is complete. Heat Circuit Main Heat Attach jumper wire to the bottom contact of a thermostat. Connect the other insulated alligator clip to the top contact of the Heat thermostat (5th from left) once the heat pilot light illuminates. The heat pilot light should turn off and the damper starts to open. Remove jumper wire from both contacts, the heat pilot light illuminates and the damper starts to close. pilot light illuminates. The auxiliary heat pilot light should turn off. Remove jumper wire from both contacts when test is complete. Low Temperature Circuit. The Low Temperature circuit can be tested for proper function immediately after fresh eggs have been loaded into the machine. Using an insulated jumper wire, connect one clip to bottom contact of one of the thermostats. Attach the other clip to the top contact of the Low Temperature thermostat (2nd from left). The Low Temperature light on the Information Panel should go out and the humidity spray will come on. Remove the jumper wire, the Note: If the bell does not ring to indicate high temperature, motor off and/or power off, check the battery, the battery connections or the alarm circuit. Replace pilot lights as required. Be careful during this examination of the control box since the power has not have been disconnected. Warning: If rewiring or relay replacement is required, turn off the power. Failure to do so could result in injury. Auxiliary Heat Attach jumper wire to the bottom contact of a thermostat. Connect the other insulated alligator clip to the top contact of the Auxiliary Heat thermostat (4th from left) once the auxiliary heat

7 spray will stop and the Low Temperature light will come on. Humidity Circuit To check the High Humidity Light on the Information Panel remove the wick from the humidistat. Replace the wick once the test has been completed. The Low Humidity light on the Information Panel should be checked following each set of fresh eggs. Motor Off Circuit Turn off the fans and unplug one motor. Then, turn the fans back on. The Motor Off light on the Warning: The tray frames will turn when air lines are connected, possibly causing injury. Therefore, ensure that no one is working within the tray frames or any other component of the incubator racks when you are connecting the air lines. information panel should illuminate and the audible alarm should ring. Repeat the process, switching off the fans each time before each motor is unplugged. This checks each fan motor off switch for correct function. Power Off Check Turn off the power to the incubator. All the lights for the machine being tested should go out on the Information Panel causing the audible alarm to ring. ROUTINE MAINTENANCE FOR INCUBATORS Refer to the checklist on page 117. BEFORE EVERY SET Egg Tray Frames Before loading egg racks, check the egg tray frame turning mechanism. Connect the air lines to the compressed air supply. If any rubbing or binding occurs, locate and fix the problem. Check the turn sensors and cables by using a battery-operated tester. Space Saver Intake Duct Check the spacing of the intake duct. The correct spacing is 5/8 inches (15.5 mm) and the duct should be parallel with the centre post on both sides. Replace or repair damaged parts as required. AFTER EVERY TRANSFER Incubator Racks Grease all castor wheels and plate bearings after sanitizing the incubator racks. One or two pumps of a grease gun should suffice. Any more will result in forcing grease out through the rubber seals. WEEKLY Spray Nozzles Clean the spray nozzles. After cleaning, check the water nozzle spray pattern. It should be a 60 degrees fan pattern and there should be no excessive dripping. If the nozzles are not producing the correct spray pattern, they may need to be replaced or the water pressure may be too low. Check the water spray nozzles for correct distance from the ceiling and correct positioning. Refer to page 136 for specific measurements. Dismantle the spray nozzle for cleaning. Spray Nozzle Condition Both water pressure and nozzle condition affect droplet size and number, which in turn, affects how efficiently moisture is absorbed into the air. Inevitably, some water droplets injected into the air stream are deposited on surfaces or objects in the flow path. When water is laden with minerals, the solids are left behind as the water evaporates. Note: The spray nozzles are located in front of the fans. To avoid injury, turn off the fans before removing the nozzles. Use a small, narrow stiletype stepladder to stand upon when disconnecting the nozzles. Nozzles block or partially block. The spray pattern is disrupted and excessive dripping occurs. Drip pans, rack tops, extrusions, panels and sensors quickly become encrusted with these deposits. Not only is this unsightly, but cleaning becomes difficult, protective coatings rapidly diminish and corrosion is accelerated. Routine maintenance becomes unpleasant and machine performance is reduced. Low water pressure, partially blocked nozzles, or poor spray pattern can result in uneven temperature distribution, measured at the exit end of the machine, e.g., top section temperature is highest while the bottom section is lowest. Therefore, maintain the spray nozzles to specifications for optimum performance. Refer to page 42 for water pressure and water quality specifications. To Clean Spray Nozzles Disconnect the nozzles at the Kwik coupler. Remove the nozzles from the body and dismantle. Clean the nozzle components in an ultrasonic cleaner. Alternatively, soak the parts in pure white vinegar or other mild solvent; thoroughly rinse. Do not use a wire to clean the orifice. This could result in damage and an incorrect spray pattern. To Check the Water Pressure Check the water pressure at the nozzles by inserting a gauge fitted for the Kwik connect into the coupling. The pressure should be at least 65 psi (5 bars). Water Pan Check the water pan level. Water pans should remain relatively dry. If not, excessive spraying probably has occurred. If one pan is full and the other empty, check for blocked nozzles on the empty side. Otherwise, check for poor incubator room conditions. The optimum room temperature is 80.0 F (26.6 C), with a relative humidity of 50 to 60 percent. Door Seals Check door seals for torn or missing door gaskets. Threshold Gasket. Replace if worn. Gaskets on rack baffle, side wall and venturi. Check both sides. Air Compressor Regulator

8 Replace missing or worn gaskets. Damaged door gaskets can result in poor air flow. Threshold Gaskets Check the threshold gasket for wear. If it is damaged, replace it. Curtains Check incubator rack curtains and brackets for damage. Any split or damaged curtains should be replaced. Rubber Gaskets Check all rubber gaskets on the rack baffle, side wall and venturi for damage. Replace any gaskets that are torn or damaged. Check the amperage of each heater. be between 11 and 14 amperes. If not, replace the heater element. Procedures on page 93. Avoid splashing water on motors and electrical connections. All motors and electrical connections must be dry before the incubator is restarted and warmed. Once the incubator has reached the appropriate temperature and humidity, the egg-filled racks can be returned in their correct order to the incubator. Proceed to check the following systems. (The best Note: If fan motors are repaired or rewound, it is recommended that revolutions per minute (rpm) be checked when the motors are reinstalled in an incubator. Use motors of similar rpm (± 2.5%) in each incubator. Do not mix low rpm motor with high rpm motors and vice versa. should be identical. The damper openings should be 1/2 in. (13 mm) when the damper is in the fully closed position. Fan Motors, Switches and Blades Clean fan motor off switches, blades and motors during complete clean-out and sanitation. Refer to Chapter 5 - Cleaning Procedures on page 93. Fan Blade Spacing and Motor RPM Compressor Drain the water from the air compressor and filter/ Note: To avoid injury, turn off the fans and turn off power before unplugging or working with fans. Before switching the fans on again, allow them to stop completely. If you do not, some of the fans may run backwards, upsetting the air flow. All fans should run in a counter-clockwise direction when viewed from behind the motor. If a fan does run backwards, simply switch it off, allowing it to stop before turning it on. trap regularly. Older air compressor regulators are mounted near the entrance of the incubator. The compressed air moisture trap is not self-draining. On newer models, drain the air compressor regulator by opening the petcock at the base of the automatic drain trap; closing it when all water has been drained. All compressor tanks have a drain petcock located on the underside. Open the petcock and drain until the escaping air is clear of water or water vapour. MONTHLY Heat Rods Use an ampere clamp (or amp probe) to check the amperage of each heater. The reading should Fans Check for excessive fan vibration. If you are unable to read the nameplate on the motor clearly or the motor frame assembly is rattling, the fan is vibrating too much. Before determining the cause of the excessive vibration, turn off the fans and turn off the power to the incubator. Inspect the motor mounts for loose bolts and connections, the motor for worn bearings, and the fan blade for correct pitch or distortion. See pages 138 to 142 for fan specifications. If vibration continues, replace the motor or fan blade. EVERY THREE MONTHS Wash and Sanitize Thoroughly clean the interior of the incubator. There is no need to leave one incubator empty for this purpose, although some hatcheries prefer to do so. Eggs can be held in other incubators (position 6) or grouped together in a warm hallway. The inside of the incubator can be washed and sanitized using a team of three or four people. Organized properly, it should take no longer than 45 minutes to one hour to complete. Refer to Chapter 5 - Cleaning time to check these components is after eggs have been loaded into the incubator.) Damper System Checked for proper opening and closing. The arrow on the knob on the drive box will indicate if the damper is closing or opening. Check for the following potential problems: If the damper opens when the main heat is on, check for reversed wiring (EM Controls only). If the incubator calls for main heat, and the damper is not moving and is open more than 1/2 in. (13 mm) the damper drive motor may need replacing. If the knob on the drive box is turning but the damper is not moving, replace the plastic drive block on the threaded rod in the damper drive. The drive motor should be turning at 5-1/2 to 6 revolutions per minute. Both the intake and exhaust damper slides should move freely without binding. Also, the size of both openings Note: If the fan blade does not appear to be static, i.e., the mark appears, disappears, reappears, the strobe light flash rate may be set x2, x3, x4. (multiple of desired rpm) too high or too low. Adjust flash rate to rpm value on the nameplate. Water Line Strainer Upon completion, check the fan spacing. See page 138 to 142 for fan spacing for current motor mount PB4723 as well as older motor mounts. Procedure for Checking RPM Jamesway suggests the use of a strobe light to check rpm, as no physical contact with the motor is required and all motors can be checked at one time. With Note: practice Close fit the of strobe all racks light is essential can also for be proper used to air flow. Incubator racks must never have a space between them of more than 1/4 inch (6.35 mm) top or bottom. If shifting of the floors or a loose levelling screw pushes the tracks out of level, adjust the tracks.

9 identify fan blade defects. Check the rpm when the motor is under load, i.e., when incubator is in normal operation and filled with eggs. Plug strobe light into power source. Stand Maintenance Schedule for PT100 Incubator Controls All of the items mentioned below should be checked, as scheduled. Refer to page 106 and your control manual for additional notes. All other items should be assessed as to their operating condition either satisfactory or unsatisfactory. Unsatisfactory would include not operating properly, excessive wear, dirt or any potential problem. Items, not in satisfactory condition, should be repaired or replaced, and/or cleaned prior to further use. Weekly Every 3 in the entrance end of incubator. Switch on strobe light and switch off incubator lights. Adjust the strobe flash rate to a value similar to rpm marked on motor nameplate, e.g., Motor PB5146: 1625 rpm at 60 Hz, 1325 rpm at 50 Hz. Fine-tune until fan blades appear to stop. Focus on a blade that is easily identifiable (small scratch or Racks must fit closely and evenly for proper air flow. If shifting of the floors or a loose levelling screw pushes the tracks out of level, adjust the tracks. Switch Plate for Side-Door Incubators A) Sensor 1. Reservoir - clean and fill as required 2. Wick - replace 3. Probes - clean B) Calibration (See PT100SMT Controls Manual, page 86.) C) Display Panel - check the following LEDs 1. High Humidity 2. Low Humidity 3. High Temperature 4. Low Temperature 5. Fan Motor Off Switch 6. Turn Failure 7. Power Off 8. Alarms D) Control Box 1. Clean, vacuum if required 2. Wire condition 3. Terminal condition 4. Relay condition 5. Boards - position firmly (older models) Warning: The PT100 controller should only be serviced by qualified maintenance personnel. Do not attempt to service the controller while it is turned on. Some circuits are energized with 220 or 380 volts ac. They will cause serious shocks, injury or death if touched. Before servicing the control box, ensure that CB1, CB2 and CB3 are turned off. Turn the fans off. Voltage Checkpoints. If required, refer to page 88 in The PT100SMT Control and System Manual.

10 Maintenance Schedule for Electro-Mechanical Incubator Controls All of the items mentioned below should be checked, as scheduled. Refer to page 108 and your control manual for additional notes. All other items should be assessed as to their operating condition either satisfactory or unsatisfactory. Unsatisfactory would include not operating properly, excessive wear, dirt or any potential problem. Items, not in satisfactory condition, should be repaired or replaced, and/or cleaned prior to further use. Maintenance Schedule for Incubators All of the items mentioned below should be checked, as scheduled. Refer to pages All other items should be assessed as to their operating condition either satisfactory or unsatisfactory. Unsatisfactory would include not operating properly, excessive wear, dirt or any potential problem. Items, not in satisfactory condition, should be repaired or replaced, and/or cleaned prior to further use. Weekly Every 3 Months Before Every Set After Every Transfer Weekly Monthly Every 3 Months Every 6 Months A) Thermostat Board 1. Reservoir - clean and fill as required 2. Wick - replace 3. Thermostats - clean B) Information Panel 1. Wire condition 2. Relays and connections condition 3. Bulb condition C) Control Box 1. Clean, vacuum if necessary 2. Wire condition 3. Relays and connections condition 4. Bulb condition D) Check the following circuits 1. High Temperature 2. Heat 3. Humidity 4. Motor Off 5. Power Off Warning: 1. The thermostat contacts are electrically live. Therefore, before cleaning the thermostats, open the control panel and disconnect the power to the thermostats. Failure to do so could result in injury. 2. Before working on the Information Panel or Control Box, disconnect the fans and heater. 3. In order to check circuitry, switch the power on. Jamesway recommends that you use an insulated jumper wire with insulated alligator clips or probes to perform the following checks. Switch the power off after each test procedure. A) Egg Turning Mechanism 1. Turn operation condition 2. Air cylinder and fittings condition 3. Turn sensor and cable condition 4. Air lines condition 5. Air connections condition 6. Turning drop cords condition B) Space Saver Incubator 1. Intake duct position (5/8 inch or 15.5 mm) C) Incubator Racks 1. Wash and sanitize 2. General condition 3. Castors and bearing plate - grease D) Spray Nozzles 1. Clean, replace if required 2. Check spray pattern 3. Check position E) Water Pan 1. Check water level F) Doors 1. Doors seal properly 2. Doors latch properly 3. Door gasket condition 4. Threshold gasket condition Note: The air cylinders should be checked for leaks including damaged or worn parts. When checking racks and turning operation, look for excessive wear, binding or rubbing of any parts. For circuit checks, refer to page 109.

11 Maintenance Schedule for Incubators (continued) G) Rubber Gaskets 1. Baffles condition 2. Side wall condition Before Every Set After Every Transfer Weekly Monthly Every 3 Months Every 6 Months mark) and ensure that its location does not change. If the blade in the chosen position appears to be static, record the strobe flash rate. The recorded value is the revolutions per minute of the motor or motors. The reading taken with strobe light should be within ± 2.5% of rpm specified on motor nameplate. EVERY SIX MONTHS programs. Frequently cleaning with a high pressure washer subjects the hatcher to harsh conditions. ROUTINE MAINTENANCE FOR PT100 HATCHER CONTROLS Refer to the checklist on page Venturi condition H) Compressor 1. Reading 2. Water build-up? 3. Tank drain I) Heat Rods 1. Check amperage (11 to 14 amp) J) Fans 1. Fan condition (vibration?) 2. Switches, blades and motors - clean 3. Blade spacing - check 4. Motor rpm - check K) Damper 1. Opening and closing properly 2. Slides move freely 3. Damper openings equal 4. Closed position correct 5. Damper motor (5-1/2 to 6 rpm) L) General Machine 1. Wash and sanitize (See Chapter 5.) 2. Check joint, caulk as required Water Line Strainer Clean the water line strainer, which is generally located within the incoming water line and before the first incubator. Turn off the water, loosen the retaining nut, and remove the strainer screen. Flush and rinse the screen to remove debris. Replace the screen, insert and tighten the retaining nut, and turn the water back on. The frequency of cleaning will depend upon the mineral content of the water. V-Groove Tracks Check the level of the V-groove tracks if the space between any two incubator racks exceeds 1/4 in. (6.35 mm), top or bottom. If the space between two racks is greater at the top, then the track may be high at this point or low at the space between the preceding or following racks. To Level Tracking To raise tracking, turn levelling screws clockwise. To lower tracking, turn levelling screws counter-clockwise. Make sure that all wheels are in contact with the track. TWICE-WEEKLY Water Reservoir Clean the water reservoir with detergent and a bottle brush to remove chick down. Fill the water reservoir with distilled water only. This will help minimize the build-up of mineral deposits inside the reservoir. Wick Change the wick after each hatch, and after cleaning the reservoir. Mineral deposits build up in the wicking and can cause 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 in. (30 cm) in length. M) Water Strainer 1. Clean N) V-Groove Tracking 1. Level as required O) Side-Door Incubators 1. Align switch plates Switch Plates In side-door entry/exit incubators, the proper alignment of the switch plates also should be checked. Careless handling of incubator racks, such as pushing too fast, can cause the switch plates to become miss-aligned. Realign all switch plates to prevent the wheels from jamming. HATCHERS Routine maintenance of hatchers, while similar to that of incubators, includes additional concerns because of the twice-weekly cleaning and sanitizing Calibration -placement of the electro-therm (HA1071) next to the PT100 sensor

12 EVERY THREE MONTHS Probes Hard water will cause a build-up of calcium and lime on the probes. Wash them in white vinegar or other mild solvent, and rinse thoroughly with water. Failure to do so may result in deterioration. If water quality is poor, you may have to clean the probes more often. 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 Note: Remember to move the thumbwheel dials back to their original set points once the check is completed. Check the accuracy of the temperature and readings. It is important that the electro-therm (HA1071) be positioned correctly next to the PT100 probe. Allow the shaft of the electro-therm to bend. Fit the tip of the shaft into the plastic sleeve and as close to the PT100 sensor as possible. They should not touch. For the testing procedure and calibration refer to The PT100SMT Controls and System Manual, page 85. Low Humidity The low humidity LED should be flashing since the actual humidity is below normal set point. If it is not, dial the humidity thumbwheel up 2 degrees or more above the actual humidity read-out. The low humidity LED should flash. High Temperature Dial the temperature thumbwheel down one degree PX Hatcher Air Cylinder Assembly or more below the actual temperature read-out. The high temperature LED and alarm lamp should flash, the damper should start opening, the blower(s) should come on, the auxiliary damper should start to lift, the spray usually should come on, and the audible alarm should ring. Alternatively, press and hold the Test button on the display panel until a 1 appears and the audible alarm is activated. dial the temperature thumbwheel switch up two degrees or more above the actual read-out. The low temperature LED should flash. Warning: The PT100 controller should only be serviced by qualified maintenance personnel. Do not attempt to service the controller while it is turned on. Some circuits are energized with 220 or 380 Vac. They will cause serious shocks, injury or death if touched. Before servicing the control box, ensure that CB1, CB2 and CB3 are turned off. Power Off Alarms Turn off the power to the hatcher. All LEDs on the display panel should go out and the audible alarm should ring. Fan Motor Off and Door Open Alarms Turn off the fans. The alarm should ring until a door is opened. Close the door and open the other. The alarm should ring momentarily. Wait Display Panel When the hatcher is empty, check the display panel. Follow the procedures normally implemented following clean-up, such as hooking up the fans and heat ring, locating the tracking, and installing the thresholds. Do not load the hatcher racks. Close the doors and switch on the machine. Wait for the hatcher to warm up to about 90 to 95 F (32 to 35 C). Dial the temperature or humidity thumbwheel switches up or down, to simulate various machine conditions. Low Temperature The low temperature LED should be flashing since the actual temperature is below set point. If not, PT100 Control Box showing CB1, CB2 and CB3 High Humidity Dial the humidity thumbwheel down 2 degrees or more below the actual humidity read-out. The high humidity LED and alarm lamp should flash. Alternatively, remove the wick from the probe.

13 until the fans stop rotating and unplug one motor. Close the door or hold down the door switch arm to simulate a closed door. Then turn the fan back on. The motor off LED should flash and the audible alarm should ring. Repeat the process, switching off the fan before reconnecting the first motor and unplugging another. This will check each motor off current sensing device for correct functioning. For PX Hatchers Air Cylinder Check the air cylinder function by dialling the temperature down 2 degrees or more (see the High Temperature check.) The 1-inch (25 mm) primary auxiliary cooling cylinder will be activated first, followed by the 2-inch (5 cm) secondary auxiliary cooling cylinder. For 2-Door Hatchers Blowers Check blowers by dialling the temperature down 2 degrees or more (see High Temperature). The blower(s) should come on. Auxiliary Damper Check the auxiliary damper operation (see High Temperature ). When the high temperature alarm rings, open the hatcher door and visually check that the auxiliary damper lifts clear of the slide. Electro-Mechanical Hatcher Thermostat Board ROUTINE MAINTENANCE FOR ELECTRO-MECHANICAL HATCHER CONTROLS Refer to the checklist on page 130. AFTER EVERY HATCH Thermostat Board Clean after every hatch. Do not use a high pressure Warning: The thermostat contacts are electrically live. Therefore, open the control panel and disconnect the power to the thermostats before removing. Failure to do so could result in injury. mixture with a paint brush. Do not get the electrical connections wet. Check the rubber grommets that seal the angle thermometers. The foam gasket on the thermostat assembly should be inspected and replaced if necessary. If the gasket is installed on the centre post, check it before installing the thermostat assembly. If the thermostat board assembly is plugged in correctly, the bulb will illuminate when the hatcher is switched on. If it does not light up, replace the assembly immediately. Warning: For the following procedure, switch the power on. Jamesway recommends that you use an insulated jumper wire with insulated alligator clips or probes to perform the following checks. Switch the power off after each test procedure. TWICE WEEKLY Water Reservoir Clean the water reservoir with detergent and a bottle brush to remove chick down. Fill the water reservoir with distilled water only. This will help minimize the build-up of mineral deposits inside the reservoir. Wick Change the wick after each hatch, and after cleaning the reservoir. Mineral deposits build up in the wicking and can cause false readings. To Install a Wick Thermostats Hard water will cause lime deposits to form on the thermostats. Wash the thermostats in white vinegar or other mild solvent. Rinse thoroughly in cold water. The clips also should be cleaned with a fine emery cloth to remove mineral deposits. If water quality is poor, thermostats may require more frequent cleaning. The best time to clean the thermostats is after a hatch when the thermostat board is removed for cleaning. Control Box The best time to check the control box is after washing, but before transfer. (The hatcher is empty.) Note: If the bell does not ring to indicate high temperature, motor off and/or power off, check the battery, the battery connections or the alarm circuit. Replace pilot lights as required. Be careful during this examination of the control box since the power has not have been disconnected. Warning: If rewiring or relay replacement is required, turn off the power. Failure to do so could result in injury. Control Box Turn the fans off. Turn the power off. Open the control box, and examine the PT100 boards and wiring, wiring connections and relay contacts for obvious faults such as discoloured wiring, and burned or blackened areas. Pay special attention to terminals, connections and relay points. Vacuum the interior if dust, chick down or metal shavings have accumulated. After vacuuming, ensure plug connections are snug. In older models, check that the boards are firmly seated. Turn the power back on. Turn the fans back on. washer on thermostats. Instead, use compressed air to remove fluff from all parts of the thermostat board. To sanitize, hold the thermostat board over a basin of water with disinfectant and apply the Warning: Turn off the power. Disconnect the fans and heater. Hold the top of the wicking with one hand. Gently slide over the extended end of the thermostat. Seat the wicking firmly around the bulb. 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 in. (30 cm) in length. EVERY THREE MONTHS

14 Vacuum the box if dust or down has accumulated. Wires, Connections and Bulbs The check can be made with or without the thermostat board installed. Unlatch the control box cover and swing it down gently. If the thermostats are installed, be careful that the latch does not damage the angle thermometers. Check the wiring, wiring connections and relay contacts for obvious faults, such as discoloured wiring, or burned or blackened areas. Pay special attention to relays points, connections and terminals. Check for burnt out bulbs. High Temperature Circuit Using the jumper wire, connect one clip to Terminal 38 on TB2. Attach the other clip to Terminal 5 on TB1. The high temperature pilot light should come on, the damper should start opening, the auxiliary damper should lift, and the alarm should ring. The heat pilot light should stay on. Blower Circuit Leave the clip connected to Terminal 38 on TB2 and attach the other clip to Terminal 7 on TB1. The blower light and motor (Big J) or motors (Super J) should come on. The heat pilot light should stay on. alarm should ring. If one door is opened, the alarm should stop ringing. When the door is closed, the alarm should ring. Open the other door. This should cause the alarm to stop ringing. The heat pilot light should stay on. Power Off Check Close the doors. Turn off the power to the hatcher. All of the pilot lights on the control box should go out, and the alarm should ring. ROUTINE MAINTENANCE FOR HATCHERS Refer to the checklist on page 131. AFTER EVERY HATCH Wash and Sanitize Thoroughly wash and sanitize hatcher racks, dollies and the interior of the hatcher. Refer to Chapter 5 - Spray Nozzle Condition Both water pressure and nozzle condition affect droplet size and number, which in turn, affects how efficiently moisture is absorbed into the air. Inevitably, some water droplets injected into the air stream are deposited on surfaces or objects in the flow path. When water is laden with minerals, the solids are left behind as the water evaporates. Nozzles block or partially block. The spray pattern is disrupted and excessive dripping occurs. Drip pans, rack tops, extrusions, panels and sensors quickly become encrusted with these deposits. Not only is this unsightly, but cleaning becomes difficult, protective coatings rapidly diminish and corrosion is accelerated. Routine maintenance becomes unpleasant and machine performance is reduced. Low water pressure, partially blocked nozzles, or poor spray pattern can result in uneven temperature distribution, measured at the exit end of the machine, e.g., top section temperature is highest while the bottom section is lowest. Therefore, maintain the spray nozzles to specifications for optimum performance. Refer to page 42 for water pressure and water quality specifications. Threshold Gasket After clean-up, reseal joints as required. Heat Circuit Connect the jumper wire to Terminal 38 on TB2 and Terminal 11 on TB1. The heat pilot light should go out, the damper should start opening, and the spray should come on. Dismantle the spray nozzle for cleaning. Cleaning Procedures on page 93 for this procedure. Avoid splashing water on motors and electrical connections. All motors and electrical connections must be dry before the hatcher is restarted and warmed. To Clean the Spray Nozzles Remove the exhaust duct at the back of the hatcher. Disconnect the Kwik connect coupler from the Humidity Circuit Using a second jumper wire, bridge Terminals 38 on TB2 and 12 on TB1. The spray should stop, and the pilot light should go out. TWICE-WEEKLY Spray Nozzles Use only one or two pumps when greasing the castor wheels. Motor Off Circuit Close the doors. Connect the alligator clips to Terminal 36 or 36A on TB2 and Terminal 2 on TB1. The motor off pilot light should come on, and the Clean the spray nozzles. After cleaning, check the water nozzle spray pattern. It should be a 60 degrees fan pattern and there should be no excessive dripping. If the nozzles are not producing the correct spray pattern, they may need to be replaced or the water pressure may be too low. Clean and sanitize the area around the damper slide.

15 spray nozzle assembly, loosen the wing nuts, and lift to remove. Unfasten the nozzles from the body and dismantle. Use an ultrasonic cleaner to clean the spray nozzle components. Alternatively, they can be soaked in pure white vinegar or other mild acid solvent. Thoroughly rinse with water. Do not use a wire to clean the orifice as it is likely to cause damage. This will result in an incorrect spray pattern. When reassembling the hatcher after clean-up, centre the spray nozzles on the fan shafts and fastened securely. To Check the Water Pressure Check the water pressure at the nozzles by inserting a gauge fitted for the Kwik connect into the coupling. The pressure should be at least 65 psi (4.5 bars). Warning: To avoid injury, turn off the fans and turn off power before unplugging or working with fans. Note: Before switching the fans on again, allow them to stop completely. If you do not, some of the fans may run backwards, upsetting the air flow. All fans should run in a counter-clockwise direction when viewed from behind the motor. If a fan does run backwards, simply switch it off, allowing it to stop before turning it on. Exhaust Duct Check for torn or missing gaskets before installing. Replace any gaskets if necessary. joints. If new sealant is required, warm the inside of the cabinet to remove moisture from the crevices. Using a dry clean cloth or paper towel, remove any residue with alcohol. Re-caulk with silicone sealant. Hatcher Racks Grease all castor wheels and plate bearings after sanitizing the hatcher racks. One or two pumps of a grease gun should suffice. Any more will result in forcing grease out through the rubber seals. For 2-Door Hatchers Blower Unplug, unlatch and remove the blower box. Clean and sanitize the area around the damper slide. Using an air hose clean the fins of the blower fan. Replace the box and plug in the blower(s). MONTHLY Fans Check for excessive fan vibration. If you are unable to read the nameplate on the motor clearly or the motor frame assembly is rattling, the fan is vibrating too much. Before determining the cause of the excessive vibration, turn off the fans, turn off the power to the hatcher and unplug the motor. Inspect the fan stand or motor mounts for loose bolts and connections, the motor shaft for worn bearings, and the fan blade for correct pitch or distortion. See page 140 for fan specifications. If vibration continues, replace the motor or fan blade. Heat Rings Note: If fan motors are repaired or rewound, it is recommended that revolutions per minute (rpm) be checked when the motors are reinstalled. Use motors of similar rpm (± 2.5%) in each hatcher. Do not mix low rpm motor with high rpm motors and vice versa. Use an ampere clamp (or amp probe) to check the amperage of each heater. The reading should be between 6 and 8 amperes. If not, replace the heater element. Check the heater for correct operation. The best time to do this is immediately after transfer, when the hatcher is calling for heat. Use an ampere clamp to check the amperage of the heater. Note: If the fan blade does not appear to be static, i.e., the mark appears, disappears, reappears, the strobe light flash rate may be set x2, x3, x4. (multiple of desired rpm) too high or too low. Adjust flash rate to rpm value on the nameplate. olds are considered normal. If other light is visible, such as along the top or bottom corners of the doors, adjust the door latches. For PX Hatchers Air Cylinder Control Assembly After clean-up, check all air cylinders and air cylinder control assembly fittings and fasteners. Adjust and tighten any that are loose. If air pressure is high, above 25 psi (1.7 bars), the extreme, rapid, back and forth movement of the piston in each cylinder can cause buddy nuts, jam nuts and socket set screws to loosen. The air pressure should be lowered to the recommended 20 psi (1.4 bars) by adjusting the regulator on the filter assembly. See the PX Hatcher installation and parts manual. EVERY THREE MONTHS Fan Motors and Blades Door Seals Check for torn or missing door gaskets. Replace any gaskets if necessary. Damaged gaskets will result in poor air flow. Threshold Gaskets Check the threshold gaskets for tears. Torn or missing threshold seals will result in poor hatching conditions in the lower trays. Therefore, keep all threshold seals in good order. Switch off the power, lift the cover off the control box, clamp around one of the heat ring wires (either number 10 or 50), and switch the power back on. The reading should be between 6 and 8 amperes. If it is not, replace the heat ring. Remember that with electro-mechanical controls only, if the damper slide is open more than 1/8 in. (3.175 mm), the heat ring will not draw any current. With PT100 controls, the heat rings will operate regardless of damper opening. WEEKLY All Joints After clean-up, check the silicone sealant used on all Use an ampere clamp to check the amperage of the heater. Cabinet Finally, inspect the cabinet for signs of penetrating light. Stand inside the cabinet with the threshold installed and the doors closed. Small areas of light around door switch arms and at the ends of thresh-

16 Clean fan motor during complete clean-out and sanitation. See pages 94 to 96. Turn off the fan motors, Clean the blades and motors with a damp sanitized cloth or brush. Be careful not to bend the blades when cleaning. Do not use a high pressure washer on the motors. Check the fan spacing upon completion. Turn the hatcher back on. Fan Blade Spacing and Motor RPM Upon completion, check the fan spacing. See page 140 for fan spacing for current motor mounts. Procedure for Checking RPM Jamesway suggests the use of a strobe light to check rpm, as no physical contact with the motor is required and all motors can be checked at one time. With practice the strobe light can also be used to identify fan blade defects. Check the rpm when the motor is under load, i.e., when hatcher is in normal operation and filled with eggs. Plug strobe light into power source. Stand in the entrance end of the hatcher. Switch on strobe light and switch off hatcher lights. Adjust the strobe flash rate to a value similar to rpm marked on motor nameplate, e.g., Motor PB5146: 1625 rpm at 60 Hz, 1325 rpm at 50 Hz. Fine-tune until fan blades appear to stop. Focus on a blade that is easily identifiable (small scratch or mark) and ensure that its location does not change. If the blade in the chosen position appears to be static, record the strobe flash rate. The recorded value is the revolutions per minute of the motor or motors. The frequency of cleaning the water line strainer will depend upon the mineral content of the water. Maintenance Schedule for PT100 Hatcher Controls All of the items mentioned below should be checked, as scheduled. Refer to page 119 and your control manual for additional notes. All other items should be assessed as to their operating condition either satisfactory or unsatisfactory. Unsatisfactory would include not operating properly, excessive wear, dirt or any potential problem. Items, not in satisfactory condition, should be repaired or replaced, and/or cleaned prior to further use. A) Sensor 1. Reservoir - clean and fill as required 2. Wick - replace 3. Probes - clean B) Calibration (See PT100SMT Controls Manual, page 86.) C) Display Panel - check the following LEDs 1. High Humidity 2. Low Humidity 3. High Temperature 4. Low Temperature D) Alarms 1. Power Off Alarm 2. Fan Motor Off and Door Open Alarms E) PX Hatcher 1. Air Cylinder condition F) 2-Door Hatchers 1. Blowers condition 2. Auxiliary Damper condition G) Control Box 1. Clean, vacuum as required 2. Wire condition 3. Terminal condition 4. Relay condition 5. Boards - position firmly (older models) Twice Weekly Every 3 Warning: The PT100 controller should only be serviced by qualified maintenance personnel. Do not attempt to service the controller while it is turned on. Some circuits are energized with 220 or 380 volts ac. They will cause serious shocks, injury or death if touched. Before servicing the control box, ensure that CB1, CB2 and CB3 are turned off. Turn the fans off. Voltage Checkpoints. If required, refer to page 88 in The PT100SMT Controls and System Manual.

17 Maintenance Schedule for Electro-Mechanical Hatcher Controls Maintenance Schedule for Hatchers All of the items mentioned below should be checked, as scheduled. Refer to pages 122 and your control manual for additional notes. All other items should be assessed as to their operating condition either satisfactory or unsatisfactory. Unsatisfactory would include not operating properly, excessive wear, dirt or any potential problem. Items, not in satisfactory condition, should be repaired or replaced, and/or cleaned prior to further use. All of the items mentioned below should be checked, as scheduled. Refer to pages 124 to 128. All other items should be assessed as to their operating condition either satisfactory or unsatisfactory. Unsatisfactory would include not operating properly, excessive wear, dirt or any potential problem. Items, not in satisfactory condition, should be repaired or replaced, and/or cleaned prior to further use. A) Thermostat Board 1. Wash and sanitize 2. Grommet condition 3. Gasket condition 4. Operating properly 5. Reservoir - clean and fill as required 6. Wick - replace 7. Thermostats - clean B) Control Box and Information Panel 1. Wire condition 2. Relays and connections condition 3. Bulb condition C) Check the following circuits 1. High Temperature 2. Blower 3. Heat 4. Humidity 5. Motor Off 6. Power Off After Every Hatch Twice Weekly Every 3 Months A) Hatcher Racks and Dollies 1. Wash and sanitize 2. General condition 3. Castors and bearing plate - grease (racks only) B) General Machine 1. Wash and sanitize (See Chapter 5.) 2. Check joints, caulk as required 3. Check for light penetration C) Spray Nozzles 1. Clean, replace if required 2. Check spray pattern 3. Check position 4. Check pressure - 65 psi (4.5 bars) D) Exhaust Duct 1. Gasket condition E) Doors 1. Doors seal properly 2. Doors latch properly 3. Door gasket condition 4. Threshold gasket condition After Every Hatch Twice Weekly Weekly Monthly Every 3 Months Warning: 1. The thermostat contacts are electrically live. Therefore, before cleaning the thermostats, open the control panel and disconnect the power to the thermostats. Failure to do so could result in injury. 2. Before working on the Control Box and Information Panel, disconnect the fans and heater. 3. In order to check circuitry, switch the power on. Jamesway recommends that you use an insulated jumper wire with insulated alligator clips or probes to perform the following checks. Switch the power off after each test procedure. F) Damper 1. Opening and closing properly 2. Slides move freely 3. Damper openings equal (PX Hatcher only) 4. Closed position correct 5. Damper motor (5.5 to 6 rpm) G) PX Hatcher 1. Air cylinder For circuit checks, refer to page 123.

18 Maintenance Schedule for Hatchers (continued) H) 2-Door Hatcher 1. Blower clean and sanitize 2. Blower thorough cleaning and sanitizing 3. Check auxiliary damper I) Heat Rings 1. Check amperage (6 to 8 amp) J) Fans 1. Fan condition (vibration?) 2. Switches, blades and motors - clean 3. Blade spacing - check 4. Motor rpm - check K) Water Strainer 1. Clean After Every Hatch Twice Weekly Weekly Monthly Every 3 Months The reading taken with strobe light should be within ± 2.5% of rpm specified on motor nameplate. Damper System The arrow on the knob of the drive box will indicate whether the damper is closing when the machine calls for heat. The damper should be opening when the heat pilot light is off. After clean-up and before egg transfer, while the hatcher is warming, check for the following potential problems: If the knob on the drive box is turning but the damper is not moving, replace the plastic drive block on the threaded rod in the damper drive. The drive motor always should turn at 5-1/2 to 6 revolutions per minute. The intake damper slide should move freely, without binding. Also, the opening should be set at 1/8 in. (3.2 mm) in the fully closed position. the gasket, if necessary. Blower Remove the blower box and thoroughly clean the inside of the blower. Remove dirt from hard to reach areas using compressed air. Clean dirt from the blower blades using a paint brush dipped in disinfectant. After thoroughly cleaning the blower and box, check the gasket around the base. Replace it if necessary. Reinstall the blower box, oil the bearings, plug in and check. Water Line Strainer Clean the water line strainer, which is generally located within the incoming water line and before the first hatcher. Turn off the water, loosen the retaining nut, and remove the strainer screen. Flush and rinse the screen to remove debris. Replace the screen, insert and tighten the retaining nut, and turn the water back on. The frequency of cleaning will depend upon the mineral content of the water. If the damper is not moving but open more than 1/8 in. (3.2 mm), the sigma relay (EM Controls only) or damper motor should be replaced. ROUTINE MAINTENANCE FOR VENTILATION EQUIPMENT For 2-Door Hatchers Check for the following potential problem: If the damper is opening when the heat light is on, the wiring may be reversed (EM Controls only). Auxiliary Damper Lift the auxiliary damper, check the gasket around the opening, then release. The lid should be under pressure from the spring in the motor and compress the gasket slightly. If not, remove the damper lid from the crank arm. Adjust the arm so it is more or less parallel with the angle of the motor mount bracket. Reattach the lid and test again. Scratch marks on the roof of the blower box also could mean incorrect assembly. See the installation and parts manual for more details. Replace A routine maintenance program is an integral part in keeping incubator and hatcher circulation problems to a minimum. A suggested maintenance schedule for ventilation equipment includes: AS REQUIRED Humidifiers Service the humidifiers according to geographical and climatic conditions. Furnaces Clean or replace filters. Cooling Units Clean or replace the filters.

19 Maintenance Schedule for Ventilation All of the items mentioned below should be checked, as scheduled. Refer to the preceding page. All other items should be assessed as to their operating condition either satisfactory or unsatisfactory. Unsatisfactory would include not operating properly, excessive wear, dirt or any potential problem. Items, not in satisfactory condition, should be repaired or replaced, and/or cleaned prior to further use. A) Humidifiers 1. Service for climatic conditions B) Furnaces 1. Clean filters, replace as required 2. Check belt tension and condition 3. Grease and inspect bearings 4. Check damper actuation 5. Inspect vents 6. Clean and lubricate motor 7. Tighten mounting hardware 8. Inspect and tighten electrical connections 9. Clean blower C) Cooling Units 1. Clean filters, replace as required 2. Check belt condition and tension 3. Grease and inspect bearings 3. Check damper actuation 4. Inspect vents, if combination heating/cooling unit D) Evaporative Coolers (during cooling season) 1. Float and water level 2. Water distribution 3. Belt tension and condition 4. Pulley alignment 5. Pad condition and placement 6. Grease and inspect bearings 7. Inspect cowlings 8. Tighten mounting hardware 9. Inspect and tighten electrical connections 10. Clean blowers As Required Weekly Monthly Every 6 Months Maintenance Schedule for Ventilation (continued) E) Exhaust Fans 1. Belt tension and condition 2. Grease and inspect bearings 3. Inspect pulley alignment 4. Clean blades 5. Check damper actuation 6. Inspect and tighten electrical connections 7. Tighten mounting hardware As Required Weekly Monthly Every 6 Months

20 SPECIFICATIONS FOR VENTILATION COMPONENTS INCUBATOR DAMPER POSITIONS HATCHER DAMPER POSITIONS PX Hatcher Note: When the damper is in fully closed position, there is a spatial opening of 1/8 inch (3 mm). Note: When the damper is in fully closed position, there is a spatial opening of 1/2 inch (13 mm). Fully closed damper position for PT100 controls Fully closed damper position for PT100 controls 2-Door Hatcher Note: When the damper is in fully closed position, there is a spatial opening of 1/8 inch (3 mm). Fully closed damper position for EM controls POSITIONING OF SPRAY NOZZLES Note: To prevent dripping, keep the nozzle tip slightly higher than the elbow centre. Fully closed damper position Correct measurements for locating angle of spray nozzle assembly SPACE SAVER INTAKE DUCT For correct spacing of the Space Saver intake duct, refer to page 101.

21 GENERAL CONSIDERATIONS FOR FAN BLADE SPACING FAN BLADE SPACING FOR 50 HZ AREA - OLDER MOTOR MOUNT 1. When adjusting the fan blade spacing, use the specifications for you particular blade and motor mount. These specifications can be found on the following pages. 2. Irrespective of the blade or the motor mount, all fans should be almost centred in the venturi, i.e., half of the fan blade depth should be located slightly under half of the venturi depth. See illustration. 3. All motor mounts in a machine should be the same. Do not mix and match motor mounts. Note: When the blades are correctly spaced, the solid red line and the dotted red line should meet on the same vertical plane. Correct spacing between fan blades and older motor mount Blade rotation for 50 Hz fans

22 FAN BLADE SPACING FOR 60 HZ AREA - OLDER MOTOR MOUNT FAN BLADE SPACING FOR 50 HZ AREA - NEW MOTOR MOUNT Correct spacing between fan blades and new motor mount FAN BLADE SPACING FOR 60 HZ AREA - NEW MOTOR MOUNT Correct spacing between fan blades and older motor mount Blade rotation for 60 Hz fans Correct spacing between fan blades and new motor mount

23 FAN BLADE SPACING FOR HATCHERS PX Hatcher Correct spacing between fan and motor mount 2-Door Hatcher Correct spacing between fan and motor mount