Basic trouBlEshooting

In document PS501 User's Manual. MANPS501 Revision 1 (Page 81-94)

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

All Locations

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.

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 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.

After the above is checked, examine the control system.

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).

After the above is checked, examine the control system.

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.

After the above is checked, examine the control system.

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.

After the above is checked, examine the control system.

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.

After the above is checked, examine the control system.

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 voltage is absent, replace SMA109S circuit board.

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.

After the above is checked, examine the control system.

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. If voltage is absent, replace SMA109S circuit board. 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.

In document PS501 User's Manual. MANPS501 Revision 1 (Page 81-94)