Optimizing Multi Stage

Incubator Performance

Addendum to
The Chicken Operation Manual
for Multi Stage

Jamesway Incubator Company Inc.

30 High Ridge Court
Cambridge, Ont., Canada
N1R 7L3

tel: (519) 624-4646

fax: (519) 624-5803
email for customer service:
service@jamesway.com

This book and its contents are the property of the Jamesway Incubator Company Inc.
Reproduction in whole or in part, by any means, without permission of Jamesway Incubator Company Inc. is prohibited.
MANOPSCADD
2001 Jamesway Incubator Company Inc. Revision A
 Table of Contents

Chapter 1 - Optimizing Incubator Performance .............................................................................5

Introduction ......................................................................................................................................5
Why Monitor Incubator Conditions? .................................................................................................5
Hatchery Maintenance .....................................................................................................................5
Your Hatchery Maintenance Program...............................................................................................5

Chapter 2 - Monitoring Incubator Conditions to Determine Machine Performance ...................7

Monitoring Schedule for Incubators and Hatchers ...........................................................................7
Entrance End Temperature ..............................................................................................................9
Procedure to Measure Entrance End Temperature ...................................................................10
Exit End Temperature .....................................................................................................................11
Procedure .................................................................................................................................11
Internal Incubator Pressure ...........................................................................................................12
Procedure .................................................................................................................................12
Damper Performance .....................................................................................................................13
Incubator Damper Position at Set ..............................................................................................13
Incubator Damper Position at Transfer .......................................................................................13
E/M Incubators ...........................................................................................................................13
Time of Transfer ..............................................................................................................................15
Monitor the Hatch ...........................................................................................................................16

Chapter 3 - Controlling Other Variables to Improve Performance ..............................................17

Grouping of Eggs Flock Age and Egg Size .................................................................................17
Problems Caused by Grouping Eggs Incorrectly ...........................................................................17
Optimum Grouping of Eggs ...........................................................................................................17
Pre-incubation and Pre-warming of Eggs ......................................................................................17
Partial and Skipped Set .................................................................................................................18
Skipped Set .................................................................................................................................18
Partial Set ...................................................................................................................................18

Chapter 4 - General Rules for Adjusting Set Times .....................................................................19

Chapter 5 - Analysing Overall Performance .................................................................................21

Variation of Air Cell Size .................................................................................................................21
Hatcher Residue Breakout .............................................................................................................21
Fresh Egg Breakout .......................................................................................................................21
Troubleshooting Performance .........................................................................................................21
1. Uneven Temperature, Side to Side ..........................................................................................21
2. Uneven Temperature, Top to Bottom ...................................................................................... 21
3. Dampers Not in Range ............................................................................................................22
4. High Early Embryo Mortality ...................................................................................................22
5. High Late Embryo Mortality .....................................................................................................22
6. Static Pressure Out of Range .................................................................................................22

Chapter 6 - Specifications: Jamesway Incubators and Hatchers ...............................................23

Systems using PT-100 Controls .....................................................................................................23
Systems with Electro-Mechanical Controls ....................................................................................24
Chapter 7 - Hatchery Maintenance ................................................................................................25
Fan Blade Spacing and Motor RPM. ..............................................................................................27
Procedure for Checking RPM .....................................................................................................27
Spray Nozzles and Humidity Water Quality ...................................................................................28
Recommendations ......................................................................................................................28
Spray Nozzle Condition ...............................................................................................................28
Space Saver Intake Duct ...............................................................................................................29

4 Optimizing Multi Stage Incubator Performance

Chapter 1 - Optimizing Incubator
Performance
Introduction
The Jamesway multi-stage incubator is an efficient
material handling and incubation system, producing
strong, healthy, active chicks. The basic operational
principles and procedures outlined in this addendum
provide the necessary information to ensure its opti-
mum performance. By following these routine and
preventative guidelines, you will consistently produce
quality chicks, economically, year round.
Both monitoring and maintenance programs are re-
quired to optimize machine performance. Maximum
benefit will not be gained if one is implemented with-
out the other.
Hatchery Maintenance
The Jamesway PT-100 controlled machines are de-
signed to be low maintenance, but do require proper
upkeep for optimum performance and efficiency.
Maintain the machines in the manner outlined in this
addendum, and see also:
The Chicken Operations Manual
The PT-100 Control System Manuals or the
manual relevant to your control system.
Your Hatchery Maintenance Program
Your hatchery, regardless of age, size or location,
is only as good as its routine and preventative mainte-
nance programs. Do not underestimate their impor-
tance. Adapt a program tailored to your specific needs
from the manuals mentioned above. Refer to Table 8,
page 25 for details on recommended maintenance pe-
riods and procedures.

Note: This addendum is to be used in con-

junction with the Jamesway Chicken Opera-
tions Manual. Contact your Jamesway
representative if you require a copy. For a
review of the Jamesway Multi Stage System
refer to page 1 and 2 of the Chicken Opera-
tions Manual.

Why Monitor Incubator Conditions?

Users who get the most out of their equipment rou-
tinely monitor their machines and continually evalu-
ate hatching performance. They understand that it pays
to devote time and effort to a monitoring program that
complements a sound maintenance schedule.

Our customers attest to the value of the program rec-

ommended in the following pages. Results have proven
that a routine monitoring program is a valuable in-
vestment. Jamesway recognizes that not all hatcher-
ies are the same and the schedule in this addendum
may not meet all your requirements. However, the
recommendations are generally applicable to most sys-
tems and may be used as the foundation on which to
build your monitoring program.

Optimizing Multi Stage Incubator Preformance 5

6 Optimizing Multi Stage Incubator Performance
Chapter 2 - Monitoring Incubator
Conditions to Determine Machine
Performance

Table 1 - Monitoring Schedule for Incubators and Hatchers

Check all of the items below as scheduled.

Assess each item. Unsatisfactory assessments include: values or performance not within
tolerance, imbalances, or any variance from the norm.
Investigate any discrepancy.
Resolve the problem to avoid loss.

Items to be Checked Time Reference

Entrance End Temperature See page 9
Air Temperature 24 hours post-transfer
Super J -100.3F (37.9C) 24 hours post-transfer
Big J - 100.5F (38.1C) 24 hours post-transfer
Exit End Temperature See page 11
Internal Egg 2 4 hours pre-transfer
Super J- 98.8F (37.1C) 2 4 hours pre-transfer
Big J - 99.0F (37.2C) 2 4 hours pre-transfer
SST Flat - 98.6F (37.0C) 2 4 hours pre-transfer
Internal Differential Pressure See page 12
5th / 6th Position (Six Racks per side) every 3 months
Super J - 0.50 to 0.55 w.g. (124 Pa - 137 Pa) (6th position level)
Big J - 0.40 to 0.45 w.g. (100 Pa - 112 Pa) (All positions turned)
SST Flat - 0.60 to 0.62 w.g. (149 Pa - 154 Pa) (Super J only, 5th & 6th position level)
Damper Performance PT-100 Controls See page 13
Sequence for Ideal Conditions
0.5 in. (1.27 cm) closed position Eggs set
Damper starts opening 1.0 - 1.5 hours after set
Range - 1.25 to 1.75 in. (3.18 to 4.45 cm) 4 - 6 hours after set
Damper - 0.75 1.0 in. (1.91 to 2.54 cm) After transfer
Range - 1.25 to 1.75 in. (3.18 to 4.45 cm) 0.5 hours after transfer
Range - 1.25 to 1.75 in. (3.18 to 4.45 cm) for next 3 - 4 days
(continued)

Optimizing Multi Stage Incubator Preformance 7

 Table 1 - Monitoring Schedule (continued)
Items to be Checked Time Reference
Damper Performance - E/M Controls See page 13
Sequence for Ideal Conditions
0.5 in. (1.27 cm) - closed position Eggs set
Damper starts opening 1.0 - 1.5 hours after set
Range - 1.0 to 1.5 in. (2.54 to 3.81 cm) 4 - 6 hours after set
Damper - 0.75 in. (1.91 cm) After transfer
Range - 1.0 to 1.5 in. (2.54 to 3.81 cm) 0.5 hours after transfer
Range - 1.0 to 1.5 in. (2.54 to 3.81 cm) for next 3 - 4 days
Time of Transfer See page 15
1. Same Day as Hatch e.g. Normally early in week
Monday (Set Thursday) 444 hours of incubation 12 hours 6th position
Tuesday (Set Friday) 444 hours of incubation 12 hours 6th position
e.g., Set 6:00 a.m. Transfer 6 p.m.
2. Day after Hatch e.g. Normally late in week
Friday (Set Monday) 432 hours of incubation 24 hours 6th position
Saturday (Set Tuesday) 432 hours of incubation 24 hours 6th position
e.g., Set 6:00 a.m. Transfer 6:00 a.m.
Monitor Hatch See page 16
Chicks Hatched 12 hours prior to pull
50 - 60% out of shell 12 hours prior to pull
10% still wet / just hatched 12 hours prior to pull
Flock Grouping in Incubator See page 17
Young flock - 20% Age 26 - 33 weeks
Prime flock - 60% Age 34 - 52 weeks
Old flock - 20% Age 53 + weeks

8 Optimizing Multi Stage Incubator Performance

Entrance End Temperature

Position 2

Position 1

Illustration 1: Entrance End Temperature

Monitoring Locations. Use Electro-therm,
HA1071.

A useful method to determine machine performance Side to side temperatures not in agreement indicate
is to monitor the entrance end temperatures twenty- an unsuitable environmental condition. Contributing
four (24) hours after transfer. factors such as:

Incorrect air distribution

Note: The monitoring time, 24 hours after
transfer, is specific. The internal conditions Air leakage
of the incubator are now stable. The eggs
Incorrect humidification
used for this measurment must be in an
endothermic state, i.e. requiring heat. There- Egg size imbalance
fore, entrance end eggs are used as they
always require heat. Other miscellaneous problems
require immediate attention.
The entrance end temperature twenty four (24) hours
Unsatisfactory performance may also result if side to
after transfer in the Super J and Big J incubators should
side temperatures are in agreement but too high or too
be 100.3F (37.94C) and 100.5F (38.06C), respec-
low, i.e., the incubator is overheating or too cool.
tively. Entrance end temperatures which vary more
than one or two tenths of a degree from the norm indi-
cate a problem and need correcting. Improper tem-
peratures contribute to an accelerated, slow or uneven Note: Once any adjustments have been
hatch. made and satisfactory machine conditions
have been achieved, it may be necessary to
Entrance End Temperature Twenty-Four (24)
adjust set times. Refer to General Rules for
Hours After Transfer
Adjusting Set Times on page 19.
Super J 100.3F 37.94C
Big J 100.5F 38.06C

Optimizing Multi Stage Incubator Preformance 9

Procedure to Measure Entrance End Temperature
Clamp the probe of the Electro-therm (HA1071),
on the egg side of the braces, at the cross brace Tip of probe should be at the junction
of the incubator rack beneath the fans. Centre the of the horizontal and diagonal braces,
tip of the probe at the junction of horizontal brace with the probe "egg side" of the braces.
and the cross braces (Illustration 2).
For the first reading, allow 10 to 15 minutes for Clip
Electro-therm
the probe of the Electro-therm to stabilize. (For
Horizontal Egg
subsequent readings, the Electro-therm will
stabilze in 3 to 5 minutes.) Brace Egg Flat
Diagonal
Brace Tray Frame
Read the temperature.
Record the temperature.
Side view showing placement
Repeat the procedure on the other side of the in- of the Electro-therm, HA1071.
cubator.

Note: Use a properly calibrated Electro-

therm. The entrance end temperature must
be taken in the incubator twenty-four (24)
hours after each transfer.

Position 2
Position 1

Illustration 2: Placement of
Electro-therm Probe

10 Optimizing Multi Stage Incubator Performance

Exit End Temperature
Electro- therm
inserted into an
infertile egg in
the middle
position.
Illustration 3: Location of Infertile Eggs and Place-
ment of Electro-therm Probe
Monitoring temperatures at the exit end (eggs in
exothermic stage, i.e. giving off heat) requires a slightly
different technique from that used at the entrance end
of the machine. Although measurements taken at the
opposite end indicate the temperature of the air exit-
ing the egg mass, readings taken in the 5th or 6th posi-
tion are the internal temperature of infertile eggs. The
internal temperature of an infertile egg should be very
close to set point, i.e., 98.8F (37.11C) for the Super
J incubator, 99.0F (37.22C) for the Big J incubator.
Internal Temperature of Infertile Eggs
Super J very close to 98.8F 37.11C
Big J very close to 99.0F 37.22C
Super J & SST very close to 98.6F 37.0C
Take and record internal egg temperatures 2 - 4 hours
before removing the eggs for transfer. For approxi-
mately twelve to eighteen hours following transfer, the
internal temperature of an infertile egg in the fifth (5th)
position will normally be two or three tenths of a de-
gree Fahrenheit (0.1C to 0.17C) lower than set point.
Large discrepancies in top to bottom and/or side to
side temperatures can lead to problems. Some of the
common factors contributing to this unevenness in
overall temperature are:
Improper humidification
Incorrect airflow and/or poor environmental con-
ditions.
Procedure
Use a properly calibrated Electro-therm with a
nonconductive sheath (HA1071).
Probe the inside of designated infertile eggs at the
top, middle and bottom tray levels of each incuba-
tor rack, both left and right (Illustration 3).
A variation of one or two tenths of a degree Fahren-
heit (0.06C to 0.17C) is not uncommon, with the
middle giving the highest reading and the top and bot-
tom at set point.
Note: Once any adjustments have been
made and satisfactory machine conditions
have been achieved, it may be necessary to
adjust set times. Refer to General Rules for
Adjusting Set Times on page 19.
Optimizing Multi Stage Incubator Preformance 11
Internal Incubator Pressure

Position 1
X
High pressure
hose attaches INCHES OF WATER

here. .2 .1
0 .1
.2
.3 lllllllllllllllllllll .3
.4 llllllllll llllll .4
.5 llllll llll .5
lll l
MAGNEHELIC

Low pressure MAX. PRESSURE 15 PSIG X

hose attaches Position 2
CAUTION

here.

HA1031

The Magnehelic Gauge The extension hose from

must be held in the vertical the high pressure port
position in order to give a should be located between
correct reading. the 5th and 6th positions.
Illustration 4: Measuring Internal Defferntial Pres-
sure

Measure incubator internal differential pressure
every third or fourth month to monitor the condition
of the rubber gaskets, curtain seal and incubator air
distribution. Investigate any inconsistencies.
Procedure
The pressure should be measured with a magnehelic
gauge and extension tube attached to the high pres-
sure port.
Locate the gauge in the entrance end of the incu-
bator. (Illustration 4.)
Run the tube through the rubber gasket surround-
ing the wheels, under the racks, and locate the end
between the fifth (5th) and sixth (6th) rack position
on the right side of the incubator.
Record the right side pressure.
Move the end of the tube to a similar location on
the left side.
Record the left side pressure.
Compare both pressure readings
Note: The magnehelic gauge must be held
in the vertical position when read. Hold the
gauge against the wall to ensure this posi-
tion.
The internal machine pressure in a Super J incubator
with 6th position level should be between 0.50 - 0.55
inches of water (124 Pa -137 Pa). The internal ma-
chine pressure in a Big J incubator should be between
0.40 and 0.45 inches of water (100 Pa - 112 Pa).

12 Optimizing Multi Stage Incubator Performance

 Internal Machine Pressure
Super J (6th position level)
0.50 - 0.55 inches of water
124 Pa - 137 Pa
Big J (all racks turned)
0.40 - 0.45 inches of water
100 Pa - 112 Pa
Super J & SST (5 and 6th position level)
th
0.60 - 0.62 inches of water
149 Pa - 154 Pa
Pressure imbalances can indicate:
Poor ventilation
Impaired air flow
Negative room or intake plenum pressure
Damaged fan blades
Wrong fan blades
Improperly adjusted fan blades
Door(s) sealing improperly
Motors running backwards
Gaskets at fan end in unsatisfactory condition
Curtains overlapping incorrectly.
Note: If the SST egg flat is used in the Su-
per J incubator, static pressure readings will
be higher between 0.60 and 0.62 inches
(149 Pa - 154 Pa) of water. Both the 5th and
6th position racks must be levelled. In the Big
J incubator all racks must be connected to
the turning system at all times. No levelling
of racks is required.
Note: Once any adjustments have been
made and satisfactory machine conditions
have been achieved, it may be necessary to
adjust set times. Refer to General Rules for
Adjusting Set Times on page 19.
Damper Performance
The optimum incubator room temperature for the
Jamesway multi-stage incubator is 80F (26.67C) and
the optimum relative humidity is 55%. A slight posi-
tive room pressure of 0.005 to 0.015 inches of water
(1.2 Pa - 3.7 Pa), compared to external ambient condi-
tions, is recommended. Jamesway has found these
conditions to be ideal, and under normal circumstances
the incubator intake and exhaust damper should open
to the optimum setting, 1.50 in. (3.81 cm) with an op-
erating range of 1.25 to 1.75 in. (3.18 to 4.45 cm) for
PT100 Controls and 1.25 in. (3.18 cm) with an oper-
ating range of 1.0 to 1.50 in. (2.54 to 3.81 cm) for
E/M Controls.
Exhaust Damper Opening
Optimum Range
PT100 Controls 1.50 in. 1.25 - 1.75 in.
3.81 cm 3.18 to 4.45 cm
E/M Controls 1.25 in. 1.0 - 1.50 in.
3.18 cm 2.54 to 3.81 cm
Incubator Damper Position at Set
Immediately after the eggs are set, the dampers close
to their minimum opening of 0.5 in.(1.27 cm). This is
the intake and exhaust closed position. The closed
position is maintained as long as the incubator tem-
perature does not exceed its set point. Once the tem-
perature exceeds set point, approximately 1.0 1.5
hours after eggs have been loaded, the damper will
start to open, and continue to do so gradually, until
reaching the optimum operating range, usually within
4 to 6 hours.
Incubator Damper Position at Transfer
Twelve to twenty-four hours after the eggs have been
set, eggs located in the 6th position will be transferred
into the hatcher. Following transfer, i.e., 6th position
racks removed, the damper will close to somewhere
between 0.75 and 1.0 in. (1.91 and 2.54 cm) for PT100
Controls and 0.75 in. (1.19 cm) for E/M Controls for
approximately 30 minutes before returning to the nor-
mal operating range. The dampers will proceed to func-
tion within the standard operating range for the next
three or four days, until the next eggs are set.
Optimizing Multi Stage Incubator Preformance 13
E/M Incubators
Damper performance may be adversely affected by
thermostat and humidistat calibration or old thermo-
stats, as well as poor clip condition, causing the heat
rods and spray to cycle incorrectly. See table below
for proper sequence.
The Electro-Mechanical machines must cycle prop-
erly.
The correct cycling sequence is: main heat on, then
auxiliary heat on; auxiliary heat off, then main heat
off.
Heat and spray should not be on at the same time. Spray
is utilized in the Jamesway machine primarily for cool-
ing, and if it is on with heat, it means the machine is
trying to heat and cool at the same time. If spray is on
when heat comes on, it should go off almost immedi-
ately.
Check thermostats. All thermostats, humidistats and
clips must be kept clean if the machine is to perform
properly. A proper wick is also needed for proper cy-
cling. Any thermostat or humidistat 5 - 7 years old
probably needs replacing due to improper calibration,
which causes the machine not to cycle or to cycle too
slowly. Even new thermostats must be matched to
achieve proper cycling. Using wrong, dirty or improp-
erly calibrated thermostats and/or humidistats will re-
sult in altered set points, which in turn will cause the
machines not to cycle properly.
Improper cycling will cause the machine to overheat
or over cool, The resulting wide swings in tempera-
ture and /or humidity will cause problems with hatch,
chick quality and performance. Use only properly cali-
brated and cleaned thermostats or humidistats in clean
clips, with properly positioned and functioning spray
nozzles, and operate the machine in correct environ-
mental conditions.
Note: In EM controlled machines, you should
see a one Fahrenheit degree (0.6C) swing
in temperature and no more than a four tenth
Fahrenheit (0.2C) swing in the wet bulb
reading. With the correct set point of 98.8F
(37.11C) and 86F (30C) the expected
swing would be 98.3F to 99.3F (36.83C
to 37.39C) dry bulb and 85.8F to 86.2F
(29.89C to 30.11C) wet bulb.

Activity Heat Function Spray Function

1. Heating temperature less than set point Aux. Heat off Spray off
Main Heat on (Wet bulb above set point)
Damper closing
2. Cooling temperature greater than set point Aux. Heat off Spray on
Main Heat off (Wet bulb below set point)
Damper opening
3. Heating temperature less than set point Aux. Heat off Spray may be on or off
Main Heat on
Damper closing
4. Repeat cycle starting with 1) above. Aux. Heat on Spray off
Main Heat on (Wet bulb above set point)
Damper closing
5. Heating temperature less than set point Aux. Heat off, Spray off
Main Heat on (Wet bulb above set point)
Damper closing

14 Optimizing Multi Stage Incubator Performance

Time of Transfer
Jamesway recommends the transfer of eggs from
the incubator into the hatcher be done at 444 hours of
incubation for Monday and Tuesday transfers and at
432 hours of incubation for Friday and Saturday trans-
fers, i.e., Monday & Tuesday transfer 444 hours, eggs
in incubator 6th position for 12 hours, Thursday & Fri-
day transfer 432 hours, eggs in incubator 6th position
24 hours.
Recommended Time of Transfer
Monday & Tuesday 444 hours of incubation
Friday & Saturday 432 hours of incubation
Most of the heat produced in the Jamesway incubator
is from embryonic development in eggs located in the
fifth (5th) and sixth (6th) rack position. If eggs are trans-
ferred too early, i.e., the sixth (6th) position removed,
the machine has to compensate for the heat lost, caus-
ing the heat rod to come on and the damper to close
more than normal.
If the eggs are transferred after eighteen and a half
days, i.e., the sixth (6th) position racks are left in the
machine longer than 444 hours, overheating will oc-
cur. The embryos in all positions will be affected and
problems, including an increase in early dead, an un-
even draggy hatch and poor chick quality, may be ob-
served.

SUN MON TUE WED THU FRI SAT

WEEK 0 1 2
WEEK 1 3 4
WEEK 2 5 6 1
WEEK 3 7 1 2 8 2 3
WEEK 4 9 3 4 10 4 5
WEEK 5 11 5 6 12 6 7
WEEK 6 13 7 8 14 8 9
WEEK 7 15 9 10 16 10 11
WEEK 8 17 11 12 18 12 13
WEEK 9 19 13 14 20 14 15

Legend
Eggs to incubator
Transfer to hatcher
Pull chicks from hatcher
Set One
Set Two

Illustration 5: Schedule for Incubation, Transfer and

Hatching of Eggs
Optimizing Multi Stage Incubator Preformance 15
Monitor the Hatch
Twelve hours prior to pull time, check on the
progress of the hatch:

Sample count three trays top, middle and bot-

tom on each side of the hatcher. Ideally 50% to
60% of the chicks should be out of the shell and
10% of them still wet, or recently hatched. (See
also Hatching the Egg, Chicken Operations
Manual, page 44.)
If your observations differ from those above, check:

Hatcher temperature
Humidity
Calibration
Equipment specifications
Ventilation
Dehydration is likely if more than 60% of birds are
out twelve hours before pull. An uneven draggy hatch
is possible if less than 50% of the chicks have hatched
twelve hours prior to pull time.

Set time adjustments may be necessary once all other

operational criteria have been checked and proved cor-
rect. (See Table 2, Monitoring Schedule for Incuba-
tors and Hatchers and the Specifications section
of your Chicken Operations Manual, pages 50 through
54, for details.)

16 Optimizing Multi Stage Incubator Performance

Chapter 3 - Controlling Other Variables
to Improve Performance
Grouping of Eggs Flock Age and Egg Size
The supply of eggs to the hatchery, which should be
reasonably constant throughout the year, originates
from a mix of young, prime and old flocks. The ratio
of young, prime and old flocks required to maintain
this constant supply is about 20:60:20, giving a mean
flock age of between 41 and 44 weeks.
To achieve optimum results from your equipment, the
mean age of the flocks producing the eggs in the incu-
bator should be 41 to 44 weeks and the ratio of eggs in
the incubator from young, prime and old flocks should
also be as close as possible to 20:60:20. The incubator
set point for your machines is the best temperature at
which to incubate the average fertile egg based on flock
age. Avoid grouping eggs according to size and age of
flock, a practice not recommended by Jamesway.
Recommended Grouping of Eggs
Mean Age 41 - 44 weeks
Ratio of Young/Prime/Old 20/60/20
Problems Caused by Grouping Eggs Incorrectly
Continually setting complete groups of small, me-
dium or large eggs, or eggs from young, prime or old
flocks, is likely to produce inconsistent results. For
example, an incubator which is usually set with small
eggs will likely have increased airflow and a lower
pressure differential. The reverse is true if large eggs
are always set in a machine. Under these circumstances
it may be necessary to adjust dry and wet bulb tem-
peratures to compensate for a lower or higher embry-
onic heat production.
Other problems may also arise. Air, like water, takes
the path of least resistance, and if one side of the set-
ter is loaded with small eggs and the other with large,
more air will flow through the side holding the smaller
eggs. This will result in a side to side airflow, tem-
perature and pressure imbalance, and is likely to cause
a reduction in hatch and chick quality from both large
and small eggs.
Optimum Grouping of Eggs
Following the recommendations given above will
ensure that airflow, temperature gradients through the
egg mass, pressure differentials across ends (entrance
and exit) and side to side balance will be consistent
from one machine to the next.
It is easier and simpler to operate and maintain all
machines in a similar manner than it is to frequently
adjust parameters for individual incubators. In gen-
eral, any deviation from recommended parameters will
result in the need to adjust incubator temperature set
points and other operational procedures, with the ever-
present likelihood for errors and decline in perform-
ance.
Note: Since it may not always be possible
to attain the flock age ratio or recommended
egg settings, some temperature adjustments
and operational changes may be required.
Should this be the case, please contact
Jamesway for further information and assist-
ance on optimizing your equipment.
Note: Refer to General Rules for Adjusting
Set Times on page 19.
Pre-incubation and Pre-warming of Eggs
Since most hatcheries do not provide proper facili-
ties in which to pre-warm eggs before placing them in
the incubators, Jamesway does not recommend pre-
warming of eggs prior to set. Set eggs directly from
the egg storage area.
Placing eggs in the corridor in front of incubators sev-
eral hours before setting does not allow all eggs to
warm up equally. Eggs in the centre of the incubator
racks will take longer to reach room temperature than
eggs near the outside.
Incorrect pre-warming of eggs can have a harmful ef-
fect on results, the most common being an uneven
hatch. Condensation on the eggshell surface may also
occur if the room into which the eggs are being placed
is improperly conditioned.
Proper pre-warming of eggs requires some method of
forcing air through the egg mass in order for all eggs
to warm at equal rates. Since most hatcheries do not
provide such facilities, Jamesway recommends direct
Optimizing Multi Stage Incubator Preformance 17
removal of the eggs from the cool room to the incuba-
tor, where adequate air movement is available. If con-
densation on the eggshells does occur, the presence of
moisture on the shell surface is brief and less likely to
have a detrimental impact on embryonic growth.
Pre-incubation in the fresh eggs can amplify any ob-
served problem with uneven or accelerated hatch. The
breeder department needs to be involved in helping to
eliminate this serious concern. Some areas to check
when determining causes of pre-incubation include:
Partial Set
Partial sets should be treated in a similar manner to
a skipped set. Place eggs against eggs, and the empty
column or spaces directly beneath the fans, when load-
ing partially set racks. See page 17 of your Chicken
Operations Manual. Depending on the number of eggs
in the racks, load the next eggs an hour or two earlier
than normal. This will compensate for some of the
embryonic heat lost when the partial set of eggs reaches
the exothermic stage.

Number of time eggs are gathered from nest

Time between gathering and placement in cooler Note: Refer to General Rules for Adjusting
Temperature and humidity of cooler Set Times on page 19.

Egg grading location.

To prevent pre-incubation and sweating of eggs, trans-
port eggs only in a controlled environment egg truck,
and handle and store eggs properly at the hatchery.
Pre-incubation should be eliminated at the source to
achieve desired results.

Note: Mottled and weak germal discs in the

fresh eggs, which can also be noted in the
fresh egg breakout, indicate some breeder
flock stress.

Partial and Skipped Set

Jamesways multi-stage incubators rely on embryo
heat to establish an optimum energy balance inside
the machine. Any disruption of this balance results in
lost heat and a need for compensation. In general, a
partial setting or skipping a set altogether is not rec-
ommended, although occasionally it may be unavoid-
able.

Skipped Set
If it is necessary to skip a set, the empty incubator
racks should be placed into the incubator in position
one, beneath the fans, in the usual manner, i.e., the
empty rack is treated as if it were full and loaded into
the incubator accordingly. To help compensate for the
loss of embryonic heat, the following set should be
loaded about two hours earlier than normal.
18 Optimizing Multi Stage Incubator Performance
Chapter 4 - General Rules for
Adjusting Set Times
Once any adjustments have been made and satisfac-
tory machine conditions have been achieved, it may
be necessary to adjust set times. In general these rules
apply:
1. At machine start up or when one or more sets are
skipped, set points are based on the days of incu-
bation of the oldest eggs in the incubator. (See
page 50 of the Chicken Operations Manual).
2. Whenever the oldest eggs in the incubator have
less than fourteen (14) days of incubation, adjust-
ments in the set point are needed, due to the loss
of embryonic heat produced by eggs in the 5th and
6th position.
3. If a single set is skipped it is beneficial to set the
next eggs two hours earlier than normal, to help
compensate for the loss of embryonic heat.
Note: Time of set adjustments is based on
the setting time of the eggs that were trans-
ferred the day before and are currently in
the hatcher. Using the examples given a
reading is taken Saturday, 24 hours after a
Friday morning transfer.
Considering that the eggs in the hatcher had
been loaded into the incubator on a Mon-
day at 6 oclock in the morning, nineteen (19)
days earlier, the set times are as follows:
Temperature 100.5F (38.06C), set time -
Monday at 6:30 to 7:00 a.m. (later)
Temperature 100.7F (38.17C), set time -
Monday at 7:00 to 8:00 a.m. (later)
Temperature 100.1F (37.78C), set time -
Monday at 5:00 to 5:30 a.m. (earlier)
Temperature 100.5F (38.06C), set time -
Monday at 4:00 to 5:00 a.m. (earlier).
7. Eggs held in storage 0 7 days, no adjustment.

4. Set eggs from young breeder flocks (26 through 8. Eggs held in storage 7 10 days set one hour ear-
33 weeks of age) two hours earlier. lier.

5. Set eggs from old flocks with low fertility (53 9. Eggs held in storage for 10 days or longer set two
weeks and older) two hours earlier. hours earlier.

6. For each one tenth (0.1F or 0.6C) variation from

100.3F (37.94C) for the Super J or 100.5F
(38.06C) for the Big J a thirty (30) minute ad-
justment is needed. For example, in a Super J in-
cubator with an entrance end temperature of
100.3F (37.94C):
If actual temperature is 100.5F (38.06C), set
eggs 1/2 to 1 hour later.
If actual temperature is 100.7F (38.17C), set
eggs 1 to 2 hours later.
If actual temperature is 100.1F (37.78C), set
eggs 1/2 to 1 hour earlier.
If actual temperature is 99.9F (37.72C), set
eggs 1 to 2 hours earlier.

Optimizing Multi Stage Incubator Preformance 19

20 Optimizing Multi Stage Incubator Performance
Chapter 5 - Analysing Overall Fresh Egg Breakout
Performance A sample of fresh eggs from the egg room from
flocks in production can be a source of valuable infor-
mation. These eggs, when broken out, can reveal ar-
Variation of Air Cell Size eas of concern such as fertility, pre-incubation and
mottling. If you are experiencing a high early death
When candling the eggs in your incubators to take lost of embryos, this sampling can help pinpoint some
the internal infertile egg temperature, you may notice probable causes. Armed with this information, you can
some variation in the size of the air cells. This indi- go to the source of the problem and take the necessary
cates improper moisture loss in the eggs, which causes corrective action.
problems with chick quality, performance and
hatchability. As conditions are corrected (as discussed
and outlined throughout this report), you should see
Troubleshooting Performance
this concern eliminated. Several factors can affect the efficiency of incuba-
tor performance. The following suggests possible ob-
servations, causes and remedies.
Note: When doing an egg breakout and ob-
serving the hatch in the hatcher trays, you 1. Uneven Temperature, Side to Side
will also notice chicks pipped both high and
low, which supports your findings during the Possible Causes:
candling that there is a variation in air cell
Improper setting
size.
Egg size not similar
Flock age not similar
Hatcher Residue Breakout Age of eggs
Analysis of the hatch residue is one of the most use- Poor airflow
ful tools for monitoring hatchery efficiency, but un-
Incorrect ventilation
fortunately each hatch day this information is thrown
away before it can be compiled. Although sorting Improper humidification
through the hatch residue is a messy job and takes some
Possible Solutions:
time, the information obtained will help you recog-
nize and monitor problems that affect the efficient Balance both sides of incubator. Use similar age
operation of your hatchery. A hatch residue breakout flock.
can identify breeder problems, as well as identify
hatchery-related problems. The implementation of a Check fans, gaskets, curtains
monthly hatch residue breakout on every flock being Check ventilation
hatched, regardless of hatchability or performance, is
recommended. Compile and monitor the information Check spray nozzles
to help make your operation more efficient and pro-
ductive. See Analysing Hatch Residue on page 87 2. Uneven Temperature, Top to Bottom
of the Chicken Operations Manual for further details. Possible Causes:

Improper humidification
Poor airflow
Incorrect ventilation
(continued)

Optimizing Multi Stage Incubator Preformance 21

Possible Solutions: 5. High Late Embryo Mortality

Check spray nozzles Possible Causes:

Check fans, gaskets, curtains Damper out of range <1.25 in. (3.18 cm) for PT100
Controls or <1.0 in. (2.54 cm) for E/M Controls
Check ventilation
Poor external conditions
3. Dampers Not in Range Incubator too cool
Optimum Range: 1.25 to 1.75 in. (3.18 to 4.45 cm) for Excessive humidification
PT100 Controls and 1.0 to 1.5 in. (2.54 to 3.81 cm)
for E/M Controls Transferring too early

Possible Causes: Possible Solutions:

Incubator too cool See Damper Performance for details

Incubator too hot Check ventilation

Poor airflow Check spray nozzles

Poor external conditions Check heat rods

Improper humidification Correct transfer time

Possible Solutions: 6. Differential Pressure Out of Range

See Damper Performance for details Ranges:
Check fans, gaskets, curtains Super J, 0.50 - 0.55 W.G. (124 Pa - 137 Pa)
Check ventilation Big J, 0.40 - 0.45 W.G. (100 Pa - 112 Pa)
Check spray nozzles SST Flat, 0.60 - 0.62 W.G. (149 Pa - 154 Pa)

4. High Early Embryo Mortality Possible Causes:

Possible Causes: Poor ventilation

Damaged gaskets
Damper out of range >1.75 in. (4.45 cm) for PT100
Controls or >1.5 in. (3.81 cm) for E/M Controls Curtain overlap
Poor external conditions Improper setting
Incubator too hot Motors running backwards
Insufficient humidification Possible Solutions:
Poor air flow See Internal Incubator Pressure for details
Transferring too late Check gaskets, curtains
Possible Solutions: See Grouping of Eggs, page 17
See Damper Performance for details Check motors
Check ventilation
Check spray nozzles
Correct transfer time
22 Optimizing Multi Stage Incubator Performance
Chapter 6 - Specifications: Jamesway
Incubators and Hatchers

Systems using PT-100 Controls

Note: If the incubator is continually full,

temperature settings should not be
changed. When new settings of eggs are
skipped, temperature settings are based
on days of incubation for the oldest eggs
in the incubator.

Table 2: Big J Incubator Set Points

Stage of Incubation Temperature Humidity

Days 1-10 99.9F (37.72C) 88.0F (31.11C)
Days 10 and 11 99.6F (37.56C) 86.0F (30C)
Days 12 and 13 99.3F (37.39C) 86.0F (30C)
Day 14 99.0F (37.22C) (winter) 86.0F (30C) (winter)
Normal Run 99.0F (37.22C) (summer) 86.0F (30C) (summer)

Table 3: Super J Incubation Set Points

Stage of Incubation Temperature Humidity

Days 1-10 99.9F (37.72C) 88.0F (31.11C)
Days 10 and 11 99.6F (37.56C) 86.0F (30C)
Days 12 and 13 99.2F (37.33C) 86.0F (30C)
Day 14 98.8F (37.11C) (winter) 86.0F (30C) (winter)
Normal Run 98.8F (37.11C) (summer) 86.0F (30C) (summer)

Table 4: Super J &SST Incubation Set Points

Stage of Incubation Temperature Humidity

Days 1-10 99.9F (37.72C) 88.0F (31.11C)
Days 10 and 11 99.6F (37.56C) 86.0F (30C)
Days 12 and 13 99.2F (37.33C) 86.0F (30C)
Day 14 98.6F (37.11C) (winter) 86.0F (30C) (winter)
Normal Run 98.6F (37.11C) (summer) 86.0F (30C) (summer)

Table 5: Big J/Super J Hatcher Set Points

Stage of Incubation Temperature Humidity

Big J at Transfer 98.5F (36.94C) 86.0F (30C)
Super J at Transfer 98.5F (36.94C) 86.0F (30C)

Optimizing Multi Stage Incubator Preformance 23

Systems with Electro-Mechanical
Controls

Note: Use start-up thermostats whenever

the oldest eggs in the incubator have 14 days
or less of incubation.

Table 6: Big J Thermostat Settings

Stage of Incubation Humidity Low Temp. High Temp. Aux. Heat Main Heat
Start-up 84-86-88F 97.0F 100.5F 99.75F 100.0F
Day 1 14 29-30-31C 36.11C 38.06C 37.64C 37.78C
PB1809 PB1812 PB1437 PB1435 PB1436
Normal Run 84-86-88F 97.0F 100.0F 98.8F 99.0 F
Day 15 18 29-30-31C 36.11C 37.78C 37.11C 37.22C
PB1809 PB1812 PB1436 PB1433 PB1434

Table 7: Super J Thermostat Settings

Stage of Incubation Humidity Low Temp. High Temp. Aux. Heat Main Heat
Start-up 84-86-88F 97.0F 100.5F 99.75F 100.0F
Day 1 14 29-30-31C 36.11C 38.06C 37.64C 37.78C
PB1809 PB1812 PB1437 PB1435 PB1436
Normal Run 84-86-88F 97.0F 100.0F 98.6F 98.8F
Day 15 18 29-30-31C 36.11C 37.78C 37.0C 37.11C
PB1809 PB1812 PB1436 PB3759 PB1433

Table 8: Big J/Super J Hatcher Thermostat Settings

Day in Cycle High Temp. Blower Heat Temp. Read. Humidity Hum. Read.
Big J 99.5F 99.0F 98.8F 98 - 100F 86.0F 84 - 88F
Day 18 21 37.5C 37.22C 37.11C 36.67 - 37.78C 30C 29-31C
PB1925 PB1434 PB1433 PB1923 PB1926 PB1924
Super J 99.5F 98.8F 98.6F 98 - 100F 86.0F 84 - 88F
Day 18 21 37.5 37.11C 37C 36.67-37.78C 30C 29-31C
PB1925 PB1433 PB3759 PB1923 PB1926 PB1924

24 Optimizing Multi Stage Incubator Performance

Chapter 7 -Hatchery Maintenance

Table 9 - Maintenance Schedule for Incubators and Hatchers

Check all items below as scheduled. See the appropriate manual for additional information.
Assess their operating condition. Unsatisfactory conditions include: not operating correctly,
excessive wear, damaged, dirty. Try to pick up on any potential problem.
Repair, replace and/or clean items not in satisfactory condition.
Items to be Checked Time Manual Reference
PT-100 Controls
1. Calibration Every 3 Months PT100SMT Controls, page 86
See page 26, this manual, for proper
placement of electro-therm.
2. Display Panel Check Every 3 Months Chicken Operations Manual, page 64 2.
3. Control Box Every 3 Months Chicken Operations Manual, page 64 3.
E/M Controls
1. Control Box & Info. Panel Every 3 Months Chicken Operations Manual, page 65 2.
PT-100 Probe & Wicking
1. Reservoir Weekly Chicken Operations Manual, page 60 1.
2. Wicking Weekly Chicken Operations Manual, page 60 2.
3. Clean Every 3 Months Chicken Operations Manual, page 64 1.
E/M Thermostats & Wicking
1. Reservoir Weekly Chicken Operations Manual, page 60 1.
2. Wicking Weekly Chicken Operations Manual, page 60 2.
3. Clean Every 3 Months Chicken Operations Manual, page 65 1.
Spray Nozzles
1. Clean Weekly Chicken Operations Manual, page 60 3.
2. Position & Water Pan Weekly Chicken Operations Manual, page 60 4.
3. Pressure Chicken Operations Manual, page 54
4. Water Quality See page 28 for specifications
Rubber Baffles & Gaskets
1. Aisle Doors Weekly Repair or replace if bent, twisted or damaged
2. Wall & Venturi Weekly Chicken Operations Manual, page 61 7.
3. Rack Baffle Weekly As above, leakage around wheel is normal
4. Threshold Gaskets Weekly Replace if torn or in poor condition
5. Doors & Latches Weekly Chicken Operations Manual, page 61 5.
Continued

Optimizing Multi Stage Incubator Preformance 25

 Table 9 - Maintenance Schedule for Incubators and Hatchers (continued)
Items to be Checked Time Manual Reference
Fan Motors
1. Vibration Monthly Chicken Operations Manual, page 63 1.
2. Motors Every 3 Months Chicken Operations Manual, page 65 2.
3. Guards & Spacing Every 3 Months See page 27 for specifications
4. Blades Every 3 Months Chicken Operations Manual, page 65 2.
5. Motor off Switches Every 3 Months Chicken Operations Manual, page 65
Incubator Racks
1. Turning Pre-load Check Every Set Chicken Operations Manual, page 62 8.
2. Check Track Level Every 6 Months Chicken Operations Manual, page 67 2.
3. Curtains Hung Correctly Daily Chicken Operations Manual, page 23 5.
General
1. Heat Rods Monthly Chicken Operations Manual, page 63 2.
2. Damper (Motor 5.5 to 6.0 RPM) Every 3 Months Chicken Operations Manual, page 66 4.
3. Intake Air Duct Every Set See below for attached for specifications

Position of PT100 temperature and

humidity sensor. Exit end.

Shaft of electro-therm bends to fit

into the space. Tip of the shaft
slides into the plastic tube next
to the temperature sensor.

Non-conductive probe
Jamesway Part #HA1071

Temperature Sensor
Electro-therm Shaft

1/4" Plastic Tubing

Tape holds tubing together
3/8" Plastic Tubing

Illustration 5: Correct placement of the Electo-therm

next to the PT100 Temperature and Humidity Sensor.

26 Optimizing Multi Stage Incubator Performance

Fan Blade Spacing and Motor RPM.
The folowing illustration shows the fan
spacing when the current motor mount PB4723 is
used. Information on spacing for older motor mounts
can be found on page 52 (Figure 93), of the Chicken
Operations Manual.
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 name-
plate.

Note: If fan motors are repaired or rewound,

Note: If the fan blade does not appear to be
it is recommended that revolutions per
static, i.e., the mark appears, disappears,
minute (RPM) be checked when the motors
reappears, the strobe light flash rate may be
are reinstalled in an incubator. Use motors
set x2, x3, x4 . (multiple of desired RPM)
of similar RPM ( 2.5%) in each incubator.
too high or too low. Adjust flash rate to RPM
Do not mix low RPM motor with high RPM
value on the nameplate.
motors and vice versa.

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 iden-
Locking Flange Nut
tify fan blade defects.
Venturi Motor Mount PB4723
Check the RPM when the motor
is under load, i.e., when incuba- Fan Blade 0.375" Between fan blades and motor mount
tor is in normal operation and for fan blades PB4351 (32 CW),
filled with eggs. and PB2825 (32 CCW).

Plug strobe light into power Motor

source.
Stand in the entrance end of in-
cubator.
0.750" Between fan blades and motor mount
Switch on strobe light and switch for fan blades PB4133 (30 CW),
off incubator lights. PB4350 (26 CW), PB2823 (26 CCW)
and PB4297 (30 CCW).
Adjust the strobe flash rate to a
value similar to RPM marked on
2.437"
motor nameplate, e.g., Motor
PB5146; 1625 rpm @60Hz; 1325 Note: The MB10513 spacer is not required
rpm @ 50 Hz. with the new motor mounts.

Fine-tune until fan blades appear

Illustration 6: Correct spacing between fan blades
to stop. Focus on a blade that is easily and motor mount.
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.

Optimizing Multi Stage Incubator Preformance 27

Spray Nozzles and Humidity Water Quality Spray Nozzle Condition
The spray nozzles in the Jamesway incubator pro- Both water pressure and nozzle condition affect
vide both humidity and cooling. A system that uses droplet size and number, which in turn, affects how
spray nozzles to atomize water requires a good clean efficiently moisture is absorbed into the air.
source of water (sediment free and minimal mineral
content) to avoid excessive scale build up. 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
Recommendations are left behind as the water evaporates. Drip pans, rack
1. Since most hatchery water supplies do not meet tops, extrusions, panels and sensors quickly become
the criteria listed below, treat the water supply to encrusted with these deposits, and nozzles block. Not
the machines, using a reverse osmosis (RO) or only is this unsightly, but cleaning becomes difficult,
other suitable water treatment system. protective coatings rapidly diminish and corrosion is
accelerated. Routine maintenance becomes unpleas-
2. Separate the water supply to the incubators and ant and machine performance is reduced.
hatchers from the water supply to the rest of the
hatchery. Low water pressure, partially blocked nozzles, or poor
spray pattern can result in uneven temperature distri-
3. The pressure at the spray nozzle must be a mini- bution, measured at the exit end of the machine, e.g.,
mum of 65 psig (5 bars) at all times. A booster top section temperature is highest while the bottom
pump may be necessary on the water line to en- section is lowest. Maintain the spray nozzles to speci-
sure the minimum pressure is maintained. The fications for optimum performance.
system must be capable of providing each incuba-
tor with 2.7 gallons (10 litres) of water per hour See Table 1 and Chicken Operations Manual, pages
and each hatcher with 1.5 gallons (5 litres) of wa- 54 and 60 for details.
ter per hour.
4. Water supplied to the incubator and hatcher spray
nozzles should meet the following characteristics:
No sediments (a 10 micron filter is suggested)
TDS (Total Dissolved Solids) less than 10.0 ppm
(parts per million)
PH range of 6-8
Hardness less than 2.0 ppm
No, iron, manganese and hydrogen sulfide, or
as close to 0.0 ppm as possible
Bacteria, zero (0) bacteria count (no detectable
amount)
Dissolved organic compounds less than 2.0 ppm
Reduced maintenance, cleaner machine interior, mini-
mal scale buildup, improved sanitation, longer equip-
ment life and optimum machine performance are some
of the benefits gained by investing in water quality.

28 Optimizing Multi Stage Incubator Performance

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 pro-

trudes into the entrance end slightly, care must be taken
Spacing between
when loading eggs. the intake duct and
the centre post must
Check the intake duct after setting eggs. be maintained at 5/8"
[1.55 cm].
Make sure it is in the proper position.
Reposition if necessary.
During routine maintenance:

Check the spacing of the intake duct. The correct

spacing is 5/8 inches [1.55 cm] and the duct should
be parallel with the centre post on both sides.
Replace or repair damaged parts as required.

Illustration 6: Correct duct spacing for Space Saver

cabinets.

Optimizing Multi Stage Incubator Preformance 29