Post on 09-Dec-2021
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 1 of 12
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
JIC-INSTP24-00004 Step 2
Cut the existing cable just outside the
techno connector.
Unscrew the connector from the motor
housing.
Keep the rubber grommet for later use.
JIC-INSTP24-00004 Step 3
Unscrew the motor wires from the
connector.
Remove and discard all connector pieces.
JIC-INSTP24-00004 Step 4
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.
JIC-INSTP24-00004 Step 5
Repeat steps 1-4 for the remaining 3
motors.
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 2 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 2 of 12
Step (picture) Step (Instructions) Step (Tools
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.
JIC-INSTP24-00004 Step 6
Disconnect the ECU power supplies from
the console, and pull the cables back
through to the ECU.
JIC-INSTP24-00004 Step 7
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.
JIC-INSTP24-00004 Step 8
Cut the cables and remove them.
Also remove the push-in cable ties.
This may all be discarded.
JIC-INSTP24-00004 Step 9
Remove the connector mounting clamps
and discard.
The ECU frame should now be free of the
previous ECU harness.
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 3 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 3 of 12
Step (picture) Step (Instructions) Step (Tools
Required)
Step (Safety &
PPE)
ECU Frame Modification
Note: This series of steps is required for all ECUs shipped without the new harness in place.
JIC-INSTP24-00004 Step 10
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.
JIC-INSTP24-00004 Step 11
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
JIC-INSTP24-00004 Step 12
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.
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 4 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 4 of 12
Step (picture) Step (Instructions) Step (Tools
Required)
Step (Safety &
PPE)
JIC-INSTP24-00004 Step 13
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.
JIC-INSTP24-00004 Step 14
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.
JIC-INSTP24-00004 Step 15
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
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 5 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 5 of 12
Step (picture) Step (Instructions) Step (Tools
Required)
Step (Safety &
PPE)
JIC-INSTP24-00004 Step 16
Use the push-in cable ties (1000692) to
secure the cables inside the ECU channel.
JIC-INSTP24-00004 Step 17
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.
JIC-INSTP24-00004 Step 18
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.
JIC-INSTP24-00004 Step 20
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
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 6 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 6 of 12
Step (picture) Step (Instructions) Step (Tools
Required)
Step (Safety &
PPE)
JIC-INSTP24-00004 Step 21
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
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 7 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 7 of 12
Step (picture) Step (Instructions) Step (Tools
Required)
Step (Safety &
PPE)
JIC-INSTP24-00004 Step 22
Ensure the liquid tight is fully tightened.
Connecting the Electric Heaters
JIC-INSTP24-00004 Step 24
Insert the three leads from the electric
heater through the 3-holed grommets and
through the liquid tights on the junction
boxes.
JIC-INSTP24-00004 Step 25
Strip the tips of each wire approximately
8-10 mm.
Either wire may be 1 or 2; the heaters are
non-polarized.
JIC-INSTP24-00004 Step 26
Connect the black wires from the heating
electrode to the provided terminal strip.
JIC-INSTP24-00004 Step 27
Strip and add a ferrule to the ground wire.
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 8 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 8 of 12
Step (picture) Step (Instructions) Step (Tools
Required)
Step (Safety &
PPE)
JIC-INSTP24-00004 Step 28
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
JIC-INSTP24-00004 Step 29
Tighten the liquid tights on the junction
box.
JIC-INSTP24-00004 Step 30
Install the lid on the junction box using the
supplied screws and tighten fully.
Use zip ties to neatly secure the wires
together.
JIC-INSTP24-00004 Step 31
Follow Steps 18-21 to connect the electric
plug.
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 9 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 9 of 12
Step (picture) Step (Instructions) Step (Tools
Required)
Step (Safety &
PPE)
ECU Support Leg Modifications (Mounting the Plug Receptacles)
JIC-INSTP24-00004 Step 32
If not already completed, mount the
templates on the ECU support legs as
indicated, and drill the holes with the #7
drill bit.
JIC-INSTP24-00004 Step 33
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
JIC-INSTP24-00004 Step 34
Mount the templates on the console and
transfer the hole locations with a punch.
JIC-INSTP24-00004 Step 35
Use a step drill bit to drill the holes out to
20 mm (13/16”).
Deburr the holes.
JIC-INSTP24-00004 Step 36
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.
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 10 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 10 of 12
Step (picture) Step (Instructions) Step (Tools
Required)
Step (Safety &
PPE)
JIC-INSTP24-00004 Step 37
Pass the console cables through the liquid
tight into the consoles.
JIC-INSTP24-00004 Step 38
Pass the cables through the liquid tights in
the bottom of the control housing.
JIC-INSTP24-00004 Step 39
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
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 11 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 11 of 12
Step (picture) Step (Instructions) Step (Tools
Required)
Step (Safety &
PPE)
JIC-INSTP24-00004 Step 40
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.
JIC-INSTP24-00004 Step 42
Trim the existing ferrules off the terminals. Strip each wire and connect to the matching wire on the motor cable using PB3678 terminals.
Jamesway Incubator Company
Part Name / Description: 1001842-5, 1002090 ECU Harness Retrofit
Instruction #: JIC-INSTP24-00004
Page 12 of 12
Operation Instruction Title: ECU Harness Retrofit – 24VDC
Revision Date: 02-04-2019 Revised By: V. Frail
Revision No. A Approved By: S. Ditner
Page 12 of 12
Step (picture) Step (Instructions) Step (Tools
Required)
Step (Safety &
PPE)
JIC-INSTP24-00004 Step 43
Zip ties the wires back towards the
outside of the motor housing.
Ensure that the wires are securely
fastened away from the motor shaft.
JIC-INSTP24-00004 Step 44
Close the lid of the motor securely, adjust
the motor lead length and secure to the
fan guard using 1 zip tie.
JIC-INSTP24-00004 Step 45
Repeat for the remaining 3 motors.