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VITALS™-Ready Handheld Valve Exerciser

1. 33 5 PSS Bees ae oe Page 33 SHIP PINS i us CE eased and GUCCI ae RO IDA ea rae anna Hae 34 Chapter 5 Operating Instructions ccc cece 35 Site Preparation 2 1 5 ipis e ee ee EA ELA RA RES 35 36 Operation E RP P PEKIN 38 ete euet qure e oboe Su oou DL Es iE 38 Powermng of the System ec P Lace PS E s wn T S p 39 Electric DIVE is sided V EC ERA DAUERN SER EX e E REA qe 39 Hydraulic Drive sus eke pez dev ote PE eS ENS 40 Pneumatic DIVE eS oo RS ens HIR RATER QR E 41 Direction and Torque Control ebore dee Rabe e e e as 41 tesa euo sou LaL eati e e at hale 41 Hydraulic Drive eG ex RE ey ee Raed ei ees es 43 Pneumatic Dive ub on gare din m Ea ede e c a US e ee ooh Bor EROR MURUS 44 Starting a New ACtiVily cou Reh chee deb LE gee FRE XAR REA Gerd 45 Performing the Valve Operation 46 Zeroing Valve Position 46 Exercismng the Valve Rod enaa in t ode me dett E Ra a 47 Resetuneg the ew PAG eee E Us 50 Logging an Unknown Valve Rot
2. 18 Control Unit Battery 18 Charging Procedures 522 bx VS up dtd e SHE I e DAD RA S Morte ea ini Dara 18 Control Unit Memory Backup Battery 21 Replacement Procegure soo e or ae Me ane Col 21 VITALS Data Logger Battery 23 Charging ProGedure o5 aod eter Mateo eT FRA REA RE 24 VITALS Data Logger Memory Backup Battery 25 Replacement Procequre oy eva etae ets ke E EUER Of gts 25 Puck dung Ou ees Ind Bue dioe ae ae ee Edu 27 E H Wachs Part No 11 MAN 02 Rev 1 0611 i Contents WAVE Handheld Valve Exerciser User s Manual Machine Specifications xe EN KORR a A MU RV a a 27 Electric Drive Torque 27 Hydraulic Drive Torque Performance 29 Pneumatic Drive Torque Performance 29 Physical Specifications a edd at A Gaeta Barge Du aie gs atr eB wae 30 ACCESSOLIGS reres i EAA ERE AG RL AEA RAO PEA AS i SR MAP UL VE ROSAS EA Bo OOS 31 Chapter 4 Assembly Disassembly and Storage 33 Environmental Requirements
3. Figure 7 9 The replaceable battery is mounted in a socket on the control unit circuit board 6 Using your fingernail or a non metallic tool remove the battery from the socket Figure 7 10 Remove the old battery from the socket 7 Press a new battery into the socket with the plus side facing up Figure 7 11 Slide the new battery into the socket with the plus side up 72 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 7 Service and Repair 8 Replace the face plate on the control unit and insert the screws PROBLEM The VITALS data logger loses settings or data when it is powered off CAUSE The memory backup battery is running dead Replace the battery using the following procedure 9 If the data logger is on turn off power using the power button 10 Remove the 4 screws on the back of the data logger 11 Carefully remove the back cover and turn it over to access the circuit board inside the data logger The battery is in a socket mounted on the circuit board as shown in Figure 7 12 Figure 7 12 The memory battery is in a socket on the circuit board 12 Using your fingernail or a non metallic tool remove the battery from the socket Some WAVE units have gas kets and some have silicone sealer Make sure you put on the gasket or re apply the sealer when replacing the face plate Any data stored in
4. eens 8 Electric System E ie RORR E eU neg eee ee ae 8 Hydraulic Systems 22 d bebes iN qa ep e segura oye ate eines 8 Phie fhalic SySIe HY Sacs oec ob nthe RARE day karten RARER a 8 Chapter 3 Introduction to the WAVE Handheld Valve Exerciser 9 Usage and Applications iet RE ces WIR pO deae darme tou DOR eA 9 Valve Maintenance Program 3 vos esa oe MEN EX REF 10 Mechanical Overview 1 2 5 5 I RERO AR a EVA SUP 11 Eleptrie DEVO d eL de bia ndo heh ote ek week og PES 11 Hydraulic Drive 4 2a cete tara sec oN Ne oe A NE atte cy A NO Moe Ce a E 12 Pneumatic Alr Dive sv us ots eva ete Rtas fee Re e E Eos teg e vs 13 Safety labeling 25 ares ote va HERE au Due as De ded dine uoa EIU iade Gub 14 Control Unit and Keypad 2 222 see 14 Special PUNCHONS 4 iro v SAN a RSS Sw Mt ae ORS de e EM OS 15 Display Window Features 12 222222 nd chased vee end ka RR eee ew ne asa 15 Keypad Eealures Suede s toute a ou tee ence E Bes Be dee ee eed 15 Data bat a Netra Lie pete LE Ls 16 Data Entry FUHCGOlS o2 ores eet ER etw kde T i TRIS 16 Data Logger System Menu 3 609524 pene hoods horreo e tees hs 17 Battery Powered Components
5. 90 12 01 3 11 213 00 90 120 07 11 225 00 90 050 07 SI 11 189 10 11 191 00 11 223 00 11 212 00 90 002 24 90 050 05 11 153 00 1 CPU P2 VITALS NOT SHOWN 115224 00 11 189 10 11 190 00 11 191 00 1 Cover Top 11 192 00 11 193 00 1 Bracket 11 220 00 2 6 Plc NOT SHOWN Terminal NOT SHOWN 11 23 00 3 Stand Off SHCS 1 4 20 X34 9011201 9 BHCS 632x58 88 O 90 120 05 2 SHCS 8 32X1 2 SS 90 120 07 CS 8 32 3 4 SS 90 901 12 4 Wire 22 GARed NOT SHOWN 90 901 21 4 Wire 22 GABlack NOT SHOWN 4 Wire 22 GA White NOT SHOWN 4 Wire 22 GA Yellow NOT SHOWN 82 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings HYDRAULIC ASSEMBLY DRAWINGS Wave Handheld Hyd 11 000 14 Part No Qty Description 11 071 00 1 Adaptor Hyd Motor 11 092 00 11 103 00 11 108 00 11 195 00 11 198 00 11 207 00 1 Battery Assembly 11 215 00 11 02 00 11 400 00 11 MAN 02 1 Manual NOT SHOWN 90 029 16 90 050 05 90 050 08 90 050 57 5 90 050 62 5 SHCS 1 4 28 X 1 1 4 E H Wachs Part No 11 MAN 02 Rev 1 0611 83 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual 05 151 00 90 075 65 11 089 00 11 088 00 90 060 10 90 028 01 11 142 00
6. Powering on the System Electric Drive 1 Plug the power cord into the appropriate electric source 110 V or 220 V 2 Press the reset button on the ground fault interrupt GFI to power up the system If the GFI pops y while operating the machine reset it and try turning the valve again If the GFI still pops switch to the low speed high torque setting E H Wachs Part No 11 MAN 02 Rev 1 0611 39 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual CAUTION Do not connect or disconnect the hydraulic hoses while the machine is operating A Figure 5 6 Press the reset button on the GFI to power on the electric WAVE handheld Hydraulic Drive Connect the hydraulic hoses as shown in Figure 5 7 8 P Figure 5 7 Attach the return hydraulic hose first The photo shows quick fit connectors installed These connectors are optional or you can install your own 2 Turn on WAVE control unit by pushing the power button on its side Figure 5 8 The start up screen will appear and then the data display screen will indicate that the control unit is ready 40 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions GJB Figure 5 8 Press the power button on the control unit to turn it on Pneumatic Drive Connect the air hose to the fitting on
7. 90 178 01 MANIFOLD ASSEMBLY 11 302 00 Qty Description 1 Relief Valve 1 Reversing_valve 2 Hose Hydraulic 1 Handle Tapered Gauge Torque Replaces P N 05 115 00 Manifold Regulator Priority Flow SPP 1 8 X 1 4 DRYSEAL SHCS 5 16 18 X1 HHCS 5 16 18 X 1 3 4 SSS 3 8 16 X 1 1 2 ADAPTER 3 8 NPT F X3 8 NPT MHP 45 Part No 05 116 00 05 151 00 11 088 0 11 089 0 11 110 0 11 141 0 11 142 0 90 028 01 90 060 1 90 061 1 90 075 65 90 178 01 1 1 3 4 Hu 84 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings Note that the same handle assembly is used for both hydraulic and pneumatic systems E H Wachs Part No 11 MAN 02 Rev 1 0611 85 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual 11 135 00 11 214 00 11 066 00 11 202 01 11 219 00 11 206 00 11 205 00 11 209 00 ee 11 217 00 4 11 216 00 Se 60 151 00 SN vd 90 029 02 7 11 203 00 25 K 11 204 00 SA amp 11 209 00 N 11 208 00 d T HANDLE AIR HYD ASSEMBLY 11 202 00 PartNo Qty Description 11 066 00 35 Wire Bell 3 Wire 11 135 00 Plug 6 Rubber 11 196 00 1 Cover Strain Gages 11 202 01 Handle Hyd Air DT 11 203 00 Cap Handle 11 204 00 Panel Connector 11 205 00 Spacer 11 206 00 Stop
8. The WAVE handheld system s control unit and the optional VITALS M data logger are powered by built in rechargable batteries There are also non rechargable mem ory backup batteries in the control unit and data logger which maintain data in memory when the units are turned off The following sections describe the battery care procedures Control Unit Battery Hydraulic Pneumatic NOTE Only the hydraulic and pneumatic powered systems include the integrated battery for powering the control unit The WAVE control unit is powered by a 7 2 V recharga ble NiMH battery in the end of the machine s handle The control unit will operate about 20 hours on a full charge Two chargers are available to charge the battery a 110 220 V AC adapter and a 12 V DC cigarette lighter adapter Use the same procedure below for either adapter Charging Procedure 1 Ifthe control unit is on press the power switch to turn The temperature should be between AN off power 32 and 104 F 0 40 C when charging the bat tery 18 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld Figure 3 10 Control unit power switch hydraulic and pneumatic systems only Press the button and release it to toggle the control unit on and off 2 Unscrew the cap on the end of the WAVE handle to access the battery charging connector Figure 3 11 The ca
9. E H Wachs 600 Knightsbridge Parkway Lincolnshire IL 60069 www ehwachs com VITALS Ready Handheld Valve Exerciser User s Manual Model P2 VITALS Ready E H Wachs Part No 11 MAN 02 Rev 1 0611 June 2011 Revision History Original December 2005 Copyright 2011 E H Wachs All rights reserved This manual may not be reproduced in whole or in part without the written consent of E H Wachs VITALS Ready Handheld Valve Exerciser Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Contents Table of Contents Chapter 1 About This Manual ccc cc cece ccc 1 Purpose of This Manual 2 25 2 00iee ieee eo ht bideae 1 Howto Use The Manudl es oo ees ie ke pea eX Goes eS eee ese ee EE 2 Symbols and Warnings s peun Ae eu IRE Qd uni ex iur de dacs va hae 2 Manual Updates and Revision Tracking 8 3 Chapter 25 Safety cis ese ene OS SSE DKS TA HOSE e Lae RETE 5 Operator Safety nisat aena Oe eee daha eee Temp Dp eno det PE 5 Protective Equipment Requirements 6 Operating Recommendations 2 522 22 ee p ura d ae ie we peewee ea ei ER 7 Safe Labels dak wea ee ete doh a utp ERA Lo PS n eee a ated DER 7 Machine Safety Md GV RE
10. SITE PREPARATION SET UP OPERATION STORING AND TRANSFERRING DATA LOGGING DATA MANUALLY E H Wachs Part No 11 MAN 02 Rev 1 0611 35 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual Typically the most comfortable height is between your waist and shoul ders f SET UP Insert the socket onto the end of the valve key and insert the pin 4 4 B A Figure 5 1 Install the socket onto the end of the valve key and insert the pin through the socket and key 2 Insertthe valve key and socket onto the drive nut on the valve 4 Figure 5 2 Put the socket onto the valve nut 3 Loosen the locking knob on the stop collar and slide the collar to a comfortable working height for the WAVE exerciser Tighten the locking knob 36 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions Figure 5 3 Slide the stop collar onto the key and use the set knob to fasten it at an appropriate height 4 Remove the WAVE handheld system from its case and place it on the valve key as shown in Figure 5 4 Slide the head of the machine down onto the stop col lar Figure 5 4 Slide the WAVE handheld system down onto the valve key and rest it on the stop collar E H Wachs Part No 11 MAN 02 Rev 1 0611 37 Chapter 5 Operating Instructions WAVE Handhel
11. Before starting turn the knob to the low est torque Setting Pneumatic Drive Direction of rotation is set by the direction control ring on the air motor Turn the indicator on the ring to the F position up to set the rotation to the right hand direction Turn the indicator to the R position down to set the rotation in the left hand direction Direction control ring Figure 5 14 Setting the direction of rotation on the air motor Forward is right hand rotation reverse is left hand rotation Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions 2 Torque is controlled using the air valve on the handle Turn the valve handle out to decrease torque turn it in to increase torque increase _ torque decrease torque Figure 5 15 Use the air flow valve to adjust the torque Starting a New Activity Press and hold the NEW ACTIVITY button on the control unit for two seconds 2 Check the mode indicator to make sure it is correct for one person operation If you are using the machine in two person mode see Two Person Operation later in this chapter The New Activity y button resets the revolution count and torque settings to O It also erases the previous activity from memory If you need to save the activity data transfer it to the VITALS data logger first Control unit screen showing o
12. E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings 11 037 00 05 036 00 db 7 8 VALVE KEY 05 402 00 Part No 05 034 00 1 Stop Collar 05 035 00 1 Locking Screw ocket 2 Opening 05 036 00 S 05 037 00 Key 1 Square 8 FeetLong 90 076 75 PIN ROLL 3 8 X2 1 2 E H Wachs Part No 11 MAN 02 Rev 1 0611 95 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual 4 KEY EXTENSION 05 403 00 Description 0509400 1 Stop Collar 05 035 00 Locking Screw 05 081 00 4 Ft X 1 Key Coupling 96 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings E H Wachs Part No 11 MAN 02 Rev 1 0611 97 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual 90 099 35 90 075 01 09 038 02 09 038 03 UNIV HANDWHEEL ADAPTER 11 401 00 PartNo Qty Description Clamp Straddle Large Torque Arm Medium Torque Arm Long FHCS 3 8 16 X 1 1 4 98 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings 11 308 00 CHARGING KIT 11 406 00 Part No Qty Description 11 056 00 Adaptor AC power for Charger 11 057 00 Cable Vehicle Accessory for Charger 11 308 00 Charger
13. INSTR WIRE 24 GAUGE BLACK SHRINK TUBING BLUE 90 046 10 1 11 029 00 LAMP LOWER 90 050 06 8 11 030 00 LAMP TOP 90 050 10 4 11 064 00 LATE HANDLE 90 050 12 6 11 068 00 ASHER LOCK 90 056 05 6 11 072 00 SHIM BEARING 90 060 15 4 11 074 00 SEAL DRIVE ADAPTOR 90 060 20 8 11 118 00 HANDLE TAPERED 90 070 17 1 11 144 00 G 90 071 10 1 11 145 00 SENSOR POSITION 90 194 20 1 11 146 00 CLIP SENSOR RETAINER 11 147 00 GEAR COUNTER 11 149 00 COVER COUNTER SENSR 56 035 00 LOCKNUT BEARING 90 001 06 SHCS 6 32 THD X 5 8 LNG PART NO QTY 90 005 01 NUT 6 32 HEX 11 070 00 90 006 54 PIN 5 64 DIA X7 16 LNG ROLL 90 501 36 90 008 01 SPP 1 16 27 Dryseal 90 900 01 90 024 02 SSS 8 32 X14 90 901 13 90 028 01 SPP 1 8 X 1 4 DRYSEAL 90 901 14 90 046 05 PIN 3 16 DIAX 1 2 LNG DOWEL 90 901 15 SHRINK TUBING RED 92 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings 11 054 00 11 044 00 90 042 02 62 121 00 11 045 00 HANDLE EXTNSN ASSY 11 303 00 Part No Qty Description 11 044 00 Assy Handle EXT 11 045 00 1 Pin Quick 3 8 X 1 1 2 11 054 00 Grip Rubber 62 121 00 Lanyard 6 Lg 90 042 02 BHCS 10 32 X 1 4 E H Wachs Part No 11 MAN 02 Rev 1 0611 93 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual 94 Part No 11 MAN 02 Rev 1 0611
14. P2 DT Air Hyd E H Wachs Part No 11 MAN 02 Rev 1 0611 99 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual 100 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 9 Accessories Chapter 9 Accessories Table 1 lists accessories available for the WAVE hand held valve exerciser Part No Description 05 402 00 4 Valve key extension assembly includes stop collar 05 403 00 8 Valve key assembly includes 2 socket and stop collar 07 408 00 2 square AWWA standard ductile iron socket 05 034 00 Stop collar es VITALS data logger controller for capturing and enter ing valve information 17 304 01 Table 1 Accessories for WAVE Handheld Valve Exerciser E H Wachs Part No 11 MAN 02 Rev 1 0611 101 Chapter 9 Accessories WAVE Handheld Valve Exerciser User s Manual Part No Description VITALS 110 220 V charger and data transfer cable with O 17 227 00 27 transfer program and download access code TM j 17 409 00 VITALS 2 0 valve performance analysis software for Windows Charger kit for WAVE control unit battery includes AC 4 z 11296 09 and 12 V DC chargers N 17 228 00 Cigarette lighter adapter to charge power VITALS data tracking and logging controller during independent use 17 234 00 GPS receiver interface cable
15. User s Manual When a valve that has not been operated for a long time is turned continuously in the closing direction the tuburcu lation and sediment built up inside it get compacted This causes the torque to increase as the valve is turned As a result the valve stem can break or the sediment can jam the gates or slides before the valve is fully closed The back and forth approach recommended here is much like operating a hand tap or die Backing the tap out clears chips between the cut ting surface and the new threads Likewise backing up the valve releases debris that has been loosened from the gates stem and slides inside it Water in the system can then flush this debris away Once the valve has been fully closed it should be opened a few turns so that the higher velocity water flowing under the gates can move the remainder of the sediment downstream Valve Maintenance Program A valve that has not been operated for a number of years needs to be closed by using a series of up and down motions Occasionally crews attempting to close a difficult valve use a T handle or a cheater bar applying a great deal of pressure in one direction simply to force the valve closed This approach can break the valve stem and make the valve inoperable requiring expensive repairs The correct way to exercise a valve is to begin with a steady amount of torque in the direction necessary to close the valve moving th
16. User s Manual Chapter 8 Parts Lists and Drawings VITALS READY ELEC 11 304 ES So EU 11 1 E Mr P abel GFI Reset ushing ear Planetary lug U K late Blanking late Blanking 00 U eleif Strain U late Blanking asket 10v Assy Eibenstock ase Storage NOT SHOWN rush Eibenstock 16 2 R L NOT SHOWN witch Gear nual NOT SHOWN CS 8 32 THD X 1 LNG ERMINAL RING 10 16 14GA NOT SHOWN ERMINAL BULLET M 16GA NOT SHOWN ERMINAL BULLET F 16GA NOT SHOWN ERMINAL FLAG 1 4 16 14 GA INSULATED NOT SHOWN 11 0 90 029 1 90 501 0 90 501 4 90 501 4 90 501 49 wo 4 2 A E H Wachs Part No 11 MAN 02 Rev 1 0611 77 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual MAIN HEAD ASSY WAVE HANDHELD 220V 11 000 15 7 11 080 00 11 215 00 11 195 00 E 11 183 00 VITALS Ready ELECT 11 188 00 N Gfi 240v Breaker 4 Amp Label Gfi Reset Bushing 11 103 00 Gear Planetary 11 183 00 11 MAN 0 Plate Blanking Manua 11 501 00 11 503 0 90 029 1 90 042 0 90 501 01 90 501 42 90 501 43 90 501 49 NOT SHOWN Brush Eibenstock 16 2 R L NOT SHOWN 78 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings E H Wachs Part No 11 MAN 02 Rev 1
17. WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions Figure 5 43 READING GPS screen showing read ings for latitude and longitude READINGS is the number of GPS data samples integrated by the data logger about 30 60 seconds to synchronize When the values for latitude and longitude appear on the data logger screen press the NEXT button to con tinue 16 The data logger and GPS receiver will take 17 The PRESS gt TO STORE screen appears Push the right arrow button to save the dataset gt The data logger will return to the SELECT VALVE ID screen Figure 5 44 PRESS gt TO STORE screen The data logger will By continue receiving GPS data until you press the NEXT button How ever only the first 99 read ings will be averaged E H Wachs Part No 11 MAN 02 Rev 1 0611 63 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual You can download a copy of the log sheet from our website at www ehwachs com f LOGGING DATA MANUALLY If you are logging valve operations manually a valve exer cising log sheet is provided in Appendix A 64 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 6 Routine Maintenance Chapter 6 Routine Maintenance WAVE GEARBOX LUBRICATION Once a month check the oil level in the gearbox 1 Lay the WAVE h
18. electric motor drive E H Wachs Part No 11 MAN 02 Rev 1 0611 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual The pressure Hydraulic Drive gauge only dis 2 plays the hydraulic pressure to the pump Use the torque display on the con trol unit for an accurate read Power head ing of torque being applied to the valve Lifting handle Hydraulic motor Control unit Pressure gauge Hydraulic outlet __ Hydraulic inlet Power lever Figure 3 3 WAVE M handheld system mechanical components hydraulic motor drive 12 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld Pneumatic Air Drive Power head Lifting handle Air motor Control unit Power lever Pressure gauge Figure 3 4 WAVE handheld system mechanical components pneumatic motor drive E H Wachs Part No 11 MAN 02 Rev 1 0611 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual To avoid injury it is important that the operator stands so that the rotation of the machine pulls the handle away from his body when turning the valve key To switch torque units between lb ft y and N m press the RESET COUNT and ZERO TORQUE buttons together SAFETY LABELING The operator position label shown in
19. keep the machine running Rotate the valve to the fully open position CX Figure 5 16 Open the valve completely to set the start position 46 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions Exercising the Valve 1 When the valve is fully opened press the RESET COUNT button 2 Set the torque limit to a reasonable value depending on the size and condition of the valve Press the up arrow to increase the torque limit The torque limit setting will increase by 50 units either Ib ft or N m each time you press the button NOTE On hydraulic and pneumatic WAVE sys tems setting the torque limit is optional Exceeding the torque limit will not stop the machine You can use the torque limit feature to activate the Over Torque Limit Indicator 3 Standin the correct position to rotate the valve in the closing direction 4 Apply power Use the minimum torque setting required to keep the valve turning 5 Watch the Current Torque reading on the control unit screen As you turn the valve the torque level will probably increase as loosened debris builds up in the valve gate slides 6 Turn the valve for about 10 rotations in the closing direction then disengage power If the ANI torque limit indicator lights before 10 rota tions disengage power immediately If the valve s manu 2 facturer provides s
20. of the the data logger data transfer you will have to go back using the left arrow button to the ENTER VALVE ID screen and create a valve ID You can then go forward with the right arrow button to this point All data will be saved Figure 5 38 RETRIEVING DATA screen 60 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions data screen appears with the number of turns recorded Push the NEXT button to continue 11 When the data transfer is finished the TURNS 2 NEXT Figure 5 39 TURNS data screen the maximum torque value recorded Push the NEXT button to continue 12 The MAX TORQUE data screen appears with ex S NEXT Figure 5 40 MAX TORQUE data screen 13 The VALVE POSITION screen appears Use the up and down arrows to highlight the posi wn tion the valve was left in Push the NEXT but ton to continue If the data logger 2 returns the PRESS gt TO DOWNLOAD screen the data transfer was unsuccess ful Reposition the data log ger on the control unit and try the transfer again If there is no 2 TURNS MAX TORQUE data in the data set from the WAVE handheld or if you turned the valve manually you can enter TURNS and MAX TORQUE values manu ally Use the up arrow on the keypad to increment the val ues on each screen v Use the up and down arrows to select
21. settings on the electric motor For normal operation keep the speed switch in the high speed low torque position see Figure 5 11 If higher torque is required for instance when unseat ing a valve use the low speed high torque setting _ low speed high torque thigh speed f low torque Figure 5 11 The speed switch is on the bottom of the electric motor housing 42 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions 3 Torque is controlled using the torque control buttons on the control unit Increase torque with the up arrow or decrease torque with the down arrow Hydraulic Drive Direction of rotation is controlled by the power lever Push the lever toward the handle to rotate the head in the right hand direction Push the lever away from the handle to rotate the head in the left hand direction Forward right hand Reverse left hand direction direction Figure 5 12 Direction control on the hydraulic pow ered WAVE M handheld system 2 Torque is controlled using the torque knob on the hydraulic motor Turn the torque knob counter clock wise to increase torque Turn the knob clockwise to decrease torque E H Wachs Part No 11 MAN 02 Rev 1 0611 43 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual Figure 5 13 Set the torque using the torque con trolled knob
22. units 7 mm Ib ft or N m Display Window Features Mode Displays if controller is in one person or two per son mode Revolution count Number of revolutions in the current operation since last reset The number can be positive or negative Positive indi cates right hand clockwise direction Battery charge level Dis plays remaining battery charge in percentage Current torque Shows cur rently applied torque in Ib ft or N m Maximum applied torque Shows the maximum torque applied during the current operation Torque limit Shows the current torque limit setting Keypad Features RESET COUNT sets the counter back to zero MODE Toggles between one person and two person mode ZERO TORQUE Sets the current torque display to zero NEW ACTIVITY Resets activity data in memory NOTE all data for the current activity is lost when you push this button Increase torque limit Increases the current torque limit by 10 Ib ft or N m Decrease torque limit Decreases the current torque limit by 10 Ib ft or N m Over torque limit indica tor Lights when current torque exceeds torque limit E H Wachs Part No 11 MAN 02 Rev 1 0611 15 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual Data Entry Functions BACK Goes to the previous data entry screen NEXT Goes to the next data entry screen Left arrow right arrow Highlig
23. y the data logger will be lost when you remove the battery If you need to keep data stored in the data logger transfer it to your PC before removing the battery Use a 5 64 hex y wrench to turn the screws CAUTION Do not touch any other compo nents on the cir cuit board or use any metallic tools E H Wachs Part No 11 MAN 02 Rev 1 0611 73 Chapter 7 Service and Repair WAVE Handheld Valve Exerciser User s Manual Use a standard CR1632 3 V or equivalent watch battery CAUTION Make sure you re install the gasket before replacing the cover f A Figure 7 13 Remove the old battery from the socket 13 Slide a new battery into the socket with the plus side up Figure 7 14 Slide the new battery into the socket with the plus side up 14 Replace the back cover on the data logger and insert the screws PROBLEM The control unit battery does not fully charge the battery indicator won t go to 100 or it loses its charge quickly CAUSE The battery needs to be replaced Contact E H Wachs Company to arrange for factory service See Chap ter 10 for ordering information 74 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings Chapter 8 Parts Lists and Drawings Refer to the parts lists and associated drawings in this chap In This Chapter ter for ordering and ma
24. 0 Panel Connector 11 206 00 11 206 00 11 208 00 1 O Ring 023 11 209 00 2 Snap 11 214 00 1 Grommet 3 16 IDx 5 16 Grip OD x 1 8 Grip Thk 11 216 00 1 Connector DIN 3 Pin 11 217 00 1 Molex Shell 11 218 00 2 Molex Terminal NOT SHOWN 11 219 00 2 Strain Gauge 21 025 01 4 Cable 034 Od Nylon NOT SHOWN 21 025 02 2 Cable Loop Sleeve NOT SHOWN 60 151 00 1 Washer Spring 90 029 02 PHMS Type 25 Phillips 90 901 12 32 Wire 22 GA Red NOT SHOWN 90 901 21 32 Wire 22 GA Black NOT SHOWN 90 901 23 32 Wire 22 GA Yellow NOT SHOWN E H Wachs Part No 11 MAN 02 Rev 1 0611 89 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual Note that the same control unit assembly is used for both hydraulic and pneumatic systems 90 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings 90 112 01 11 189 10 11 191 00 11 213 00 11 223 00 DNE 11 210 00 90 002 24 11 197 00 du 11 211 00 VITALS READY AIR HYD Part No 11 19800 HYD T1 153 00 11 189 10 11 191 00 11 197 00 11 198 00 11 199 00 11 210 00 11 211 00 11 212 00 11 213 00 11 220 00 11 222 00 11 223 00 90 002224 90211201 s BHcs e32x58 58 SSCS E H Wachs Part No 11 MAN 02 Rev 1 0611 91 Chapter 8 Parts Lists and Drawings WAVE Handheld Va
25. 0611 79 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual 11 196 00 11 135 00 HANDLE ELECTRIC ASSEMBLY 11 194 00 PartNo Qty Descripion 11 066 00 3 11 123 00 11 047 00 1 Grommet 7 16 ID x9 16 Grip OD x 1 8 Grip Thk gt WIRE BELL 3 WIRE Housing Switch 11 124 00 Switch Modified 11 132 00 Terminal End 11 134 00 Plug 4 Rubber 11 135 00 Plug 6 Rubber eldment Switch Handle DT over Strain Gages train Gauge HCS 10 32 X 3 8 ERMINAL RING 10 16 14GA NOT SHOWN N O os WD 90 501 01 7 90 501 1 1 90 501 19 90 042 06 RMINAL Closed End 16 20 GA Insulated NOT SHOWN ERMINAL RING 1 4 YEL NOT SHOWN RMINAL Spade 250 Female 2 10 GA Insulated NOT SHOWN ERMINAL Flag 250 12 10 Insulated NOT SHOWN RMINAL BULLET M 16GA NOT SHOWN 4 90 501 42 90 501 50 1 90 501 49 ERMINAL FLAG 1 4 16 14 GAINSULATED NOT SHOWN ERMINAL SPADE 1 4 MALE 16 AWG INSULATED NOT SHOW 4 2 90 901 18 20 ire 16 10 Cond Cable 80 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings E H Wachs Part No 11 MAN 02 Rev 1 0611 81 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual VITALS READY ELECTRIC PartNo Qty Description
26. 1 About This Manual e Chapter 4 Assembly and Disassembly e Chapter 6 Routine Maintenance e Chapter 7 Service and Repair You will also want to refer to Chapter 8 Parts Lists and Drawings In This Chapter PURPOSE OF THIS MANUAL HOW TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES E H Wachs Part No 11 MAN 02 Rev 1 0611 Chapter 1 About This Manual WAVE Handheld Valve Exerciser User s Manual Throughout this manual refer to this column for warnings cautions and notices with supplementary information How TO USE THE MANUAL This manual is organized to help you quickly find the infor mation you need Each chapter describes a specific topic on using or maintaining your WAVE handheld valve exer ciser Each page is designed with two columns This large column on the inside of the page contains instructions and illustra tions Use these instructions to operate and maintain your WAVE valve exerciser The narrower column on the outside contains additional information such as warnings special notes and definitions Refer to it for safety notes and other information SYMBOLS AND WARNINGS The following symbols are used throughout this manual to indicate special notes and warnings They appear in the out side column of the page next to the section they refer to Make sure you understand what each symbol means and follow all instructions for cautions and warnings WARNING This s
27. 1 is available from the American National Standards Institute Inc 1430 Broadway New York NY 10018 CAUTION Personal hearing protection is recom mended when operating or working near this tool Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 2 Safety Hearing protectors are required in high noise areas 85 dBA or greater The operation of other tools and equipment in the area reflective surfaces process noises and resonant struc tures can increase the noise level in the area For additional information on hearing protection refer to Federal OSHA regulations 29 Code of Federal Regulations Section 1910 95 Occupational Noise Exposure and ANSI 12 6 Hearing Protectors Operating Recommendations CAUTION Some people experience chronic pain in their hands and arms when performing repetitive tasks or operating vibrating equipment Repetitious forceful exertion of the hands and arms can cause or aggra vate disorders such as carpal tunnel syn drome and tendonitis Use minimum hand grip force e Keep your wrists straight e Avoid prolonged continuous exposure to vibration e Avoid repeated bending of your wrists and hands SAFETY LABELS The operator position label is affixed to the handle of the WAVE handheld system It shows where you should stand depending on direction of rotation SQNVIS 5017340 30 NOLLOS
28. 11 401 00 Universal Valve Handwheel Adapter Table 1 Accessories for WAVE Handheld Valve Exerciser 102 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 10 Ordering Information Chapter 10 Ordering Information To place an order request service or get more detailed information on any E H Wachs Company products call us at one of the following numbers US 800 323 8185 International 847 537 8800 ORDERING REPLACEMENT PARTS When ordering parts refer to the parts lists in Chapter 8 Please provide the part description and part number for all parts you are ordering REPAIR INFORMATION Please call us for an authorization number before returning any equipment for repair or factory service We will advise you of shipping and handling When you send the equip ment please include the following information e Your name company name e Your address e Your phone number e A description of the problem or the work to be done In This Chapter REPLACEMENT PARTS REPAIR INFORMATION WARRANTY INFORMATION RETURN GOODS ADDRESS E H Wachs Part No 11 MAN 02 Rev 1 0611 103 Chapter 10 Ordering Information WAVE Handheld Valve Exerciser User s Manual Before we perform any repair we will estimate the work and inform you of the cost and the time required to com plete it WARRANTY INFORMATION Enclosed with the manual is a warranty card Please fi
29. Bulkhead 11 208 00 1120900 2 1121409 1 1121600 7 11 217 00 Molex Shell 11 218 00 Molex Terminal NOT SHOWN 11 219 00 Strain Gauge 21 025 01 Cable 034 Od Nylon NOT SHOWN 21 025 02 Cable Loop Sleeve NOT SHOWN 60 151 00 Washer Spring 90 029 02 1 PHMS Type 25 Phillips 90 901 12 Wire 22 GARed NOT SHOWN 90 901 21 Wire 22 GABlack NOT SHOWN 90 901 23 Wire 22 GA Yellow NOT SHOWN 86 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings Note that the same control unit assembly is used for both hydraulic and pneumatic systems 90 112 01 11 189 10 11 191 00 11 213 00 11 223 00 11 21 x m 11 210 00 90 002 24 11 197 00 ia VITALS READY AIR HYD Part No Qty Description 11 198 00 HYD 11 153 00 1 CPU P2 VITALS NOT SHOWN 11 189 10 1 Keypad P2 DT 11 191 00 1 Cover Top 11 197 00 1 Housing Controller Air Hyd 11 198 00 1 Plate Base HYD 11 199 00 1 Plate Base AIR 11 210 00 1 Switch 11 199 00 AIR 11 211 00 1 Boot 11 212 00 1 Board Round Control 11 213 00 1 Display Assembly 11 220 00 2 6 Plc NOT SHOWN 11 222 00 12 11 223 00 3 90 002 24 3 JPHMS 6 32 x7 16 Phillips 90 112 01 8 BHCS 6 32 x5 8 SS E H Wachs Part No 11 MAN 02 Rev 1 0611 87 Chapter 8 Parts Lists and Drawings WAV
30. E Handheld Valve Exerciser User s Manual PNEUMATIC ASSEMBLY DRAWINGS lt 90 060 22 v OW 11 200 00 MAIN HEAD ASSY 11 201 00 90 050 15 11 107 00 WAVE HANDHELD AIR 11 000 13 Description 11 199 00 1 Plate Base Air 11 200 00 11201 00 11 093 01 11 093 02 1 Gauge 1 5 X1 8 Pipe 11 094 00 1 Label Gauge Overlay 11 095 00 1 Adapter Motor 11 096 00 11 107 00 11 137 00 1 Nipple 11 195 00 1 Plate Blanking 11 207 00 1 Assembly Battery 11 215 00 1 Gasket 17 40 00 11 02 90 050 15 3 SHCS 1 4 20 X 1 1 2 90 060 22 SHCS 5 16 18 X 2 1 4 90 060 10 SHCS 5 16 18 X1 90 098 62 ADAPTER 1 2 NPT MX 1 2 NPT F 45 88 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 8 Parts Lists and Drawings Note that the same handle assembly is used for both hydraulic and pneumatic systems 11 135 00 11 214 00 11 066 00 11 202 01 11 219 00 11 206 00 11 205 00 11 209 00 ne 11 217 00 i Ss 11 216 00 Wo 60 151 00 ES vd 90 029 02 711 203 00 gt Ae 11 204 00 Sy 11 209 00 DS 11 208 00 im HANDLE AIR HYD ASSEMBLY 11 202 00 PartNo Qty Description 11 066 00 Wire Bell 3 Wire 11 135 00 1 Plug 6 Rubber 11 196 00 1 Cover Strain Gages 11 202 01 1 Handle Hyd Air DT 11 203400 11 204 0
31. E The memory backup battery is running dead Replace the battery using the following procedure 3 If the control unit is on turn off power to it e On electric powered systems press the OFF button on the Figure 7 6 Press the Off button on the GFI to power down the electric WAVE handheld 70 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 7 Service and Repair On hydraulic and pneumatic systems press the power switch on the side of the control unit Figure 7 7 Control unit power switch hydraulic and pneumatic systems only Press the button and release it to toggle the control unit on and off 4 Remove the 4 screws on the face plate of the control Use a 5 64 hex unit 2 wrench to turn the screws Figure 7 8 Remove the screws on the control unit face plate to open the control unit 5 Carefully remove the face plate and turn it over to CAUTION access the circuit board inside the control unit The Make sure the battery is in a socket mounted on the circuit board as control unit is shown in Figure 7 9 turned off before opening it E H Wachs Part No 11 MAN 02 Rev 1 0611 71 Chapter 7 Service and Repair WAVE Handheld Valve Exerciser User s Manual CAUTION Do not touch any other compo nents on the cir cuit board or use any metallic tools Use a standard CR1632 3 V or equivalent watch battery
32. ERATOR screen Tocontinue with the displayed operator push the NEXT button e change the operator edit the operator ID on the screen Use the left and right arrows to highlight a character and use the up and down arrows to change the value of the highlighted character Push the NEXT but ton when you are finished 7 The DOWNLOAD screen appears The data logger is now ready to download data from the WAVE sys tem Figure 5 35 DOWNLOAD screen 8 Align the data logger in the same direction as the con trol unit as shown in Figure 5 36 Four holes in the back of the data logger fit onto the four screw heads on the front of the control unit 58 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions Figure 5 36 Aligning the VITALS data logger with the WAVE handheld control unit The four holes in the back of the data logger fit onto the screws on the face plate of the control unit 9 Set the data logger onto the control unit and hold it firmly in place while performing the download E H Wachs Part No 11 MAN 02 Rev 1 0611 59 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual Figure 5 37 Downloading data to the data logger If you did not select 10 Press the right arrow button The RETRIEVING a valve ID at the 2 DATA screen will appear while data is downloaded to beginning
33. Figure 3 5 is affixed to the handle of the WAVETM handheld system to indicate where the operator should stand during use SONVIS NOLYNGdO 2 EA NMOUvIOM JO NOLDSMIG 4 amm OPERATOR STANDS A DIRECTION OF ROTATION 0 2 Figure 3 5 Operator position label CONTROL UNIT AND KEYPAD Use the electronic control unit to monitor torque and revolu tions and to change data collection settings Figure 3 6 illustrates the controller keypad Chapter 5 Operating Instructions explains how to use the controller The controller stores revolution and torque data for the cur rent valve operation You can save this data for later analy sis using the optional VITALS data logger See Storing and Transferring Data in Chapter 5 NOTE Torque values on the control unit display are in the currently selected units lb ft or N m Current units are dis played on the start up screen when you power up the con troller 14 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld Revolution count Current torque Maximum applied Battery charge level torque Mode one two person Torque limit Increase Decrease Over torque torque torque indicator Figure 3 6 WAVE M Control Unit Special Functions Press RESET COUNT and ZERO pem f TORQUE together to switch torque
34. SI ap Figure 2 1 Operator Position Label E H Wachs Part No 11 MAN 02 Rev 1 0611 Chapter 2 Safety WAVE Handheld Valve Exerciser User s Manual MACHINE SAFETY To avoid damaging your WAVE handheld valve exerciser follow these usage guidelines Check gearbox oil level at least once every month Don t store any other equipment in the WAVE handheld system s storage box Keep the end cap tightly screwed into the end of the handle to keep out dirt and moisture Electric System Make sure that the voltage output from your electrical power supply is correct for requirements of your WAVE handheld system Do not submerge the electric motor or allow it to get excessively wet Hydraulic System Do not exceed hydraulic flow of 8 gallons per minute gpm 30 liters per minute Ipm Do not exceed hydraulic pressure of 1800 psi 124 bar Every time you connect hydraulic power to the machine check hoses and fittings to make sure there are no leaks Pneumatic System Use an inline filtration system to prevent water and air borne contaminants from getting into the air motor Use an inline oiling system to lubricate the motor Use antifreeze oil when operating the system under con tinuous load and high torque settings to reduce ice buildup Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld Chapter 3 In
35. a logger before you attach it to the WAVE control unit Press and hold the POWER button on the f VITALS data logger until the power up screen appears Figure 5 28 VITALS data logger power up screen 2 Release the power button The SELECT OPTION screen appears The control unit on y the WAVE hand held system only stores the most recent data set Transfer the data to the VITALS gata logger after each valve operation If you are unable to 2 transfer data suc cessfully the win dows on the infrared ports may be dirty Wipe them clean with a soft dry cloth and try the transfer again Clean the ports on both the data logger and the control unit You can use glass cleaner if necessary DO NOT USE SOLVENTS OR OTHER CLEANERS ON THE INFRARED PORT WIN DOWS E H Wachs Part No 11 MAN 02 Rev 1 0611 55 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual Use the RESUME command to con 2 tinue completing and storing the last dataset that was in the controller data logger You must select or create a valve ID in 2 order to transfer data If there are no valve IDs in the list you must create one on the ENTER VALVE ID screen below You can enter new valve IDs at the 2 VITALS data log ger or download them to the data logger from a PC using the VITALS valve perfor mance software Figure 5 29 SELECT OPTION scre
36. andheld system upside down as shown in Figure 6 1 2 Using a 3 16 hex wrench remove the filler plug and vent hole plug as shown in Figure 6 1 Figure 6 1 Removing the filler and vent plugs In This Chapter GEARBOX LUBRICATION CALIBRATING THE TORQUE SENSOR E H Wachs Part No 11 MAN 02 Rev 1 0611 65 Chapter 6 Routine Maintenance WAVE Handheld Valve Exerciser User s Manual The maximum capacity of the gear By box is 5 oz 148 ml The recommended oil is 123 Kent Gear Oil with Moly 90 wt part no 02 401 00 3 Look into either hole to check the oil level Oil should be visible in the hole If no oil is visible pour oil into either hole until you can see oil in the other hole See Figure 6 2 Figure 6 2 Adding oil to the gearbox 5 Replace both plugs CALIBRATING THE TORQUE SENSOR Normally the torque sensor will not need to be recalibrated However if the handle has been over extended the sensor may become mis calibrated If this has happened the Cur rent Torque reading on the control unit display screen will not return to 0 when you press the RESET TORQUE but ton Calibration of the sensor is a factory service procedure See Chapter 10 Ordering Information for requesting factory service 66 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 7 Service and Repair Chapter 7 Service an
37. anual Chapter 3 Introduction to WAVE Handheld 4 Using your fingernail or a non metallic tool remove the battery from the socket Figure 3 17 Remove the old battery from the socket 5 Press a new battery into the socket with the plus side facing up Figure 3 18 Slide the new battery into the socket with the plus side up 6 Replace the face plate on the control unit and insert the screws VITALS Data Logger Battery The VITALS data logger is powered by a 7 2 V recharga ble NiMH battery pack It will operate about 6 8 hours on a full charge Two chargers are available to charge the battery a 110 220 V AC adapter and a 12 V DC cigarette lighter adapter Use the same procedure below for either adapter A an battery plate CAUTION Do not touch any other compo nents on the cir cuit board or use any metallic tools Use a standard CR1632 3 V or equivalent watch Some WAVE units have gas kets and some have silicone sealer Make sure you put on the gasket or re apply the sealer when replacing the face E H Wachs Part No 11 MAN 02 Rev 1 0611 23 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual Charging Procedure The temperature 1 Ifthe VITALS data logger is on press the should be between power button to turn it off MJ 32 and 104 F 0 40 C when 2 Connect the charger cable to the battery
38. ation 52 Two Person Operations reders wy ee Rack wd ee dow kop So ee ase 53 Storing and Transterrtup D tar 4 oes Saa EN ce cM 55 Using the VITALS Data Logger 55 Logging Data REA iS da d 64 Chapter 6 Routine Maintenance cece cece cc ccc ee cece cece hh nnn 65 WAVE Gearbox DubriealTOtE e o dace qx ae a frm bs uS 65 Calibrating the Torque Sensor 4 5 59 ERI RES ERA RSEN REGN TERRA RE SEA EAR ST 66 Chapter 7 Service and Repair ccceeeeeeeeeeeee ee ee oooeo 67 Mechanical Problems 25 4 ERETAGR ES 67 Electrical Problems x o Se Sev eu E MES WSR RO EN RR UV 70 ii Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Contents Chapter 8 Parts Lists and 75 Bleettie System Assembles s oci ek ERES E aee P yaq aes obey ah eee 76 Hydraulic Assembly aseo Level decli kien ie ier E 83 Pneumatic Assembly Drawings E T RE EEER 88 COmmoncASsembles eo DAR I E DA RE RD eb pn NR dr Oa 92 Chapter 9 Accessories rh EAE XX ee NN EE AEG CREE ORE TS 101 Chapter 10 Ordering Informati
39. charging con charging the bat nector on the front side of the VITALS data logger tery Figure 3 19 Plug the charger cable into the VITALS connector 3 Connect the power cable from the charger to the power source Figure 3 20 Plugging in the charger will start charg ing the battery 24 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld Charging a fully drained battery takes about 2 4 hours The charger will automatically shut off when the bat tery is fully charged When you are finished charging remove the charger cable from the battery charging connector VITALS Data Logger Memory Backup Battery A standard size 3 V watch battery CR1632 or equivalent maintains data in memory when the data logger is turned off This keeps your settings as well as the stored valve operation data Replacement Procedure If you do not have 2 time for a full charge you can partially charge the battery without damaging it If the data logger y starts to lose data or revert to its default settings when it is turned off replace the mem ory backup battery 1 If the data logger is on turn off power using Any data stored in the power button 2 the data logger will be lost when you 2 Remove the 4 screws on the back of the data logger remove the battery If you need to keep data stored in the data logge
40. d Repair MECHANICAL PROBLEMS PROBLEM There is fresh oil in the bottom of the storage box or on the gear head of the machine CAUSE An oil seal in the gear head is leaking There are seals on the top and bottom of the head You can replace them if you have machine press equipment to insert the new seal Otherwise return the machine for factory service Oil seals are part number 05 014 00 1 Using a small flat blade screwdriver pry out the leak ing seal You may have to pry alternately on opposite sides of the seal to remove it Figure 7 1 Pry out the old oil seal with a flat blade screwdriver In This Chapter MECHANICAL PROBLEMS ELECTRICAL PROBLEMS E H Wachs Part No 11 MAN 02 Rev 1 0611 67 Chapter 7 Service and Repair WAVE Handheld Valve Exerciser User s Manual 2 Select a press fitting that fits snugly inside the new seal and the appropriate sleeve for the fitting 3 Lay the WAVE system on a solid workbench or other level surface and put the press fitting in place Figure 7 2 Put the press fitting in place over the bearing 4 Slide the seal down over the fitting with the flat side of the seal facing up Figure 7 3 Slide the seal down onto the fitting 68 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 7 Service and Repair 5 Slide the sleeve over the press fitting Figure 7 4 Put the appr
41. d Valve Exerciser User s Manual WARNING The WAVE hand held system can produce up to 800 Ib ft 1085 N m of torque To avoid possible injury always stand so that the torque pulls the handle away from your body You can operate the WAVE hand y held exerciser with out turning on the control unit However you will not be able to monitor torque or rotations or save any data OPERATION Operator Position Always stand so that the rotation of the valve pulls the han dle of the WAVETM system away from you If you are stand ing on the wrong side of the machine and the valve sticks the increase in torque can knock you off balance or pin you against an obstacle causing injury Refer to the Operator Position label on the handle during use When standing on the correct side of the machine you will always push the power handle away from you To drive the valve key in a right hand clockwise direction stand on the motor side of the handle To drive the valve key in a left hand counter clockwise direction stand on the side oppo site the motor Figure 5 5 illustrates the correct operator position 38 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions Direction of rotation Direction of rotation Figure 5 5 The operator should always stand so that the handle of the WAVE machine pulls away from his body
42. e menu to display the second screen of commands Press the NEXT button to select the highlighted option DATA TRANSFER Puts the controller into data trans fer mode for transferring data to or from a PC e BACKLIGHT Turns the LCD backlighting on and off e VIEW STORED EXERCISE Displays a list of valve operation datasets in memory e INFORMATION Displays system information Figure 3 9 Data logger system menu screen 2 Use the up arrow to scroll back up to the first menu screen e SET DATE AND TIME Lets you change current date and time settings e UNITS Lets you change units between lb ft and e MASTER RESET Erases all stored datasets from memory E H Wachs Part No 11 MAN 02 Rev 1 0611 17 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual The electric pow ered system does y not have a control unit battery The control unit is powered on when power is supplied to the entire system The operating time on a battery charge y will be reduced if you use the backlight on the control unit screen ENABLE VITALS Allows you to turn data logging features on and off With VITALS data logging off the controller data logger is used only for control of the TM valve exerciser ENABLE GPS READ Allows you to turn GPS data logging on and off With GPS Read off the data logger will not display the READING GPS screen BATTERY POWERED COMPONENTS
43. en Use the up or down arrow to highlight NEW ACTIV ITY then press the NEXT button The SELECT VALVE ID screen appears Figure 5 30 SELECT VALVE ID screen Use the up and down arrows to highlight the 56 valve ID If you need to create a new valve ID select any ID in the list Press the NEXT button to continue Figure 5 31 Selecting a valve ID Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions 5 The ENTER VALVE ID screen appears Figure 5 32 ENTER VALVE ID screen e To continue with the selected valve ID push the NEXT button To create a new valve ID edit the ID on the screen Use the left and right arrows to highlight a character and use the up and down arrows to change the value of high gt Use the left and lighted character right arrows to highlight char acters v Use the up and down arrows to change the value of the current charac ter Figure 5 33 Creating a new valve ID NEXT button The ENTER OPERATOR screen appears The most recent operator is displayed 6 When you have edited the valve ID push the NEXT E H Wachs Part No 11 MAN 02 Rev 1 0611 57 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual Make sure the WAVE control 2 unit is powered on before you connect the data logger Figure 5 34 ENTER OP
44. ent labels from E H Wachs Company KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts In This Chapter OPERATOR SAFETY SAFETY LABELS MACHINE SAFETY Look for this symbol throughout the man ual It indicates a safety warning E H Wachs Part No 11 MAN 02 Rev 1 0611 Chapter 2 Safety WAVE Handheld Valve Exerciser User s Manual Always turn machine off before doing any adjustments or service e SECURE LOOSE CLOTHING AND JEWELRY Secure or remove loose fitting clothing and jewelry and securely bind long hair to prevent them from getting caught in moving parts of the machine KEEP WORK AREA CLEAR Keep all clutter and nonessential materials out of the work area Only people directly involved with the work being performed should have access to the area WARNING When using the electric powered WAVE handheld system avoid standing water whenever possible To avoid electrical shock do not expose electrical cord to water Protective Equipment Requirements WARNING Always wear impact resistant eye pro tection while operating or working near this equipment For additional information on eye and face protection refer to Federal OSHA regulations 29 Code of Federal Regula tions Section 1910 133 Eye and Face Protection and American National Standards Institute ANSI Z87 1 Occu pational and Educational Eye and Face Protection Z87
45. ght 8 1 2 22 cm Torque arm extension for two operators 8 ft 244 cm valve key 4 ft 122 cm valve key extension 2 square AWWA standard ductile iron socket Stop collar 15 16 drive socket Control unit battery charging kit VITALS controller data logger Cigarette lighter adapter to charge con troller data logger VITALS 2 0 valve performance anal ysis software E H Wachs Part No 11 MAN 02 Rev 1 0611 3l Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual 32 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 4 Assembly and Disassembly Chapter 4 Assembly Disassembly and Storage Your WAVE handheld valve exerciser is shipped fully assembled from the factory It is ready to operate as soon as you remove it from its storage case Use of some optional equipment requires that you install it onto the WAVE system e For instructions on transferring data to the VITALS data logger see Storing and Transferring Data in Chapter 5 For instructions on installing the extension handle see Two Person Operation in Chapter 5 ENVIRONMENTAL REQUIREMENTS Machine operation 4 to 158 F 20 to 470 C Battery charging 32 to 104 F 0 to 40 LONG TERM STORAGE The WAVE handheld system should be kept in its storage case when not
46. he opposite side of the machine as the primary operator as shown in Figure 5 27 The torque should be pulling the handle away from both operators Figure 5 27 Operating the WAVE handheld system in two person mode Start the valve operation as described under Starting a New Activity earlier in this section After pressing the NEW ACTIVITY button m press the MODE button to switch to two per son mode The mode indicator on the LCD will show the current mode 54 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions STORING AND TRANSFERRING DATA Using the VITALS Data Logger If you have the optional VITALS data logger you can transfer valve exercising data from the control unit and store it for later analysis The data logger will hold datasets from up to 100 valve operations maximum of 3000 turns allow ing you to save data in the field and download it at a conve nient time to a PC based application such as VITALS valve performance analysis software The VITALS data logger fits onto the front of the WAVE control unit Four holes in the back of the data logger align with the four screw heads on the front of the control unit Data is transferred through the two infrared ports on the face of the control unit to two ports on the back of the data logger You can enter valve and operator information on the dat
47. hts characters for edit ing in menu selections Up arrow down arrow Scroll up and down through selections in a menu MENU DIsplays closes sys tem menu POWER Turns controller on and off NOTE Not all functions of the VITALS Data Logger are used for data transfer from the WAVE handheld system These are machine control functions for other valve exercising systems The following buttons are not used STOP START DIR MODE NEW ACTIVITY RESET COUNT e Press Increase Torque Limit and Decrease A Torque Limit together to turn LCD back light on and off VITALS DATA LOGGER The optional VITALS controller data logger stores data from up to 100 valve operations maximum of 3000 revolu tions for transfer to a PC application It attaches directly to the WAVE control unit for data transfer Figure 3 7 illus trates the features of the VITALS data logger CONTROLLER DATA LOGGER JOE ome IOS Figure 3 7 VITALS controller data logger 16 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld Data Logger System Menu on the data logger screen press the Menu Press the MENU button to display the system menu f pm To exit the menu MENU button again Figure 3 8 Data logger system menu Use the up and down arrow buttons to highlight the options Scroll past the bottom of th
48. ic powered systems press the OFF button on the GFI On hydraulic and pneumatic systems press the power switch on the side of the control unit CJ UJ a v Figure 3 14 Control unit power switch hydraulic and pneumatic systems only Press the button and release it to toggle the control unit on and off 2 Remove the 4 screws on the face plate of the control unit If the control unit Ay starts to lose data or revert to its default settings when it is turned off replace the mem ory backup battery Data stored in the y control unit will be lost when you remove the battery Transfer any data you need to the VITALS gata logger before turning off the control unit Use a 5 64 hex By wrench to turn the screws E H Wachs Part No 11 MAN 02 Rev 1 0611 21 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual Figure 3 15 Remove the screws on the control unit face plate to open the control unit CAUTION 3 Carefully remove the face plate and turn it over to Make sure the access the circuit board inside the control unit The control unit is battery is in a socket mounted on the circuit board as turned off before 9 shown in Figure 3 16 opening it Figure 3 16 The replaceable battery is mounted in a socket on the control unit circuit board 22 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s M
49. in use Environmental requirements for stor age are as follows In This Chapter ENVIRONMENTAL REQUIREMENTS LONG TERM STORAGE SHIPPING E H Wachs Part No 11 MAN 02 Rev 1 0611 33 Chapter 4 Assembly and Disassembly WAVE Handheld Valve Exerciser User s Manual Machine 22 to 176 F 30 to 80 Batteries 4 to 113 F 20 to 45 SHIPPING Before transporting or shipping the WAVE handheld sys tem secure it in its storage case using the fasteners pro vided Figure 4 1 indicates the fastener locations Figure 4 1 Insert the pins to secure the WAVE hand held system and the extension handle into the storage case 34 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions Chapter 5 Operating Instructions SITE PREPARATION Select the appropriate length valve key so that the top of the key is at least waist high when inserted on the valve nut If necessary use the optional valve key extension Make sure you have a place to stand with sure footing for both feet If you have the electric drive WAVE handheld system make sure that you are not standing in water when plugging in or operating the machine Keep vehicles and any other equipment far enough away so that the handle of the WAVE handheld system can rotate around the valve key without obstruction In This Chapter
50. intenance ELECTRIC DRAWINGS BOMS There are separate sets of drawings with BOMs for the elec HYDRAULIC DRAWINGS BOMS tric hydraulic and pneumatic versions of the WAVE handheld exerciser There is also a section of this chapter for common assemblies which are the same for versions of the machine PNEUMATIC DRAWINGS BOMS COMMON ASSEMBLIES E H Wachs Part No 11 MAN 02 Rev 1 0611 75 Chapter 8 Parts Lists and Drawings WAVE Handheld Valve Exerciser User s Manual ELECTRIC SYSTEM ASSEMBLIES 11 215 00 11 195 00 VITALS Ready ELECT MAIN HEAD ASSY 11 103 00 069 00 ML 11 183 00 s 11 188 00 e 2 c E WAVE HANDHELD 110V 11 000 12 Part No Qty Description 11 041 00 1 Gf 110v 11 061 00 Breaker 8 Amp 11 069 00 Label Gfi Reset 1198000 1 11 103 00 1 Gear Planetary 11 183 00 Plate Blanking 11 184 00 Plate Blanking 11 188 00 Relief Strain 11 195 00 Plate Blanking 11 215 00 Gasket Eu 1 1 11 804 ES 1140 00 1 uoc Brush Eibenstock 16 2 R L NOT SHOWN 11 501 00 71250300 1 11 MAN 02 Manual NOT SHOWN 90 029 16 7 LHCS 8 32X1 90 042 06 BHCS 10 32 X 3 8 NOT SHOWN 90 501 01 Terminal Ring 10 18 14GA NOT SHOWN 90 501 42 Terminal Bullet M 16GA NOT SHOWN 90 501 49 2 Terminal Flag 1 4 16 14 GA INSULATI NOT SHOWN 76 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser
51. ll out the registration card and return to E H Wachs Company Retain the owner s registration record and warranty card for your information RETURN GOODS ADDRESS Return equipment for repair to the following address E H Wachs 600 Knightsbridge Parkway Lincolnshire Illinois 60069 USA 104 Part No 11 MAN 02 Rev 1 0611 E H Wachs E H WACHS Superior Equipment Complete Support 600 Knightsbridge Parkway Lincolnshire IL 60069 847 537 8800 www ehwachs com
52. lve Exerciser User s Manual COMMON ASSEMBLIES 90 050 10 90 001 06 11 027 00 11 144 00 90 050 12 11 009 00 56 035 00 11 149 00 90 046 05 11 145 00 90 006 54 11 146 00 90 005 01 90 060 20 ree 11 030 00 11 026 00 11 029 00 11 072 00 1102600 11 194 20 11 006 00 90 07 1 10 11 064 00 90 056 05 11 118 00 90 046 10 b 90 008 01 11 147 00 TE _ 11 015 01 11 007 00 90 056 05 05 014 00 70 028 01 11 022 00 MAIN HEAD ASSEMBLY inox PART NO QTY PART DESCRIPTION er ets ae a 019 00 11 005 00 70195 11 023 00 11 006 00 90 070 17 11 007 00 11 074 00 11 009 00 CAP BRGRETAINER 11 021 00 11 015 01 WASHER SPUR GEAR 90 060 15 11 019 00 BLOCK MOTOR MOUNT 11 020 00 BEARING WORM SHAFT 11 021 00 CAP WORM GEAR BRG 90 050 06 10102200 05 014 00 11 023 00 11 024 00 1102600 PART NO QTY DESCRIPTION 11 027 00 PIN 3 16 DIAX 1 LNG DOWEL SHCS 1 4 20 THD X 5 8 LNG SHCS 1 4 20 THD X 1 LNG SHCS 1 4 20 THD X 1 1 4 LNG PIN 1 4 DIA X 1 2 LNG DOWEL SHCS 5 16 18 THD X 1 1 2 LNG SHCS 5 16 18 THD X2 LNG SHCS 3 8 16 THD X 1 3 4 LNG HHCS 3 8 16 THD X 1 LNG SSS 1 2 13 THD X2 LNG NOT SHOWN PART DESCRIPTION 1 OPERATOR POS 1 BUTTSPLICE 16 14 GA TERMINAL LABEL MAUNUAL
53. n the valve to the end of travel in this direction Document the direction of rotation and number of turns required Turn the valve back in the opposite direction to its original position when the revolution counter returns to zero You can transfer the data to the VITALS data logger and record an UNKNOWN valve position Two Person Operation Read the previous sections of this chapter before using the WAVE handheld exerciser in two person mode This sec tion describes only the procedure for setting up the machine for two person mode 1 Insert the extension handle into the side of the WAVE head opposite the handle as shown in Figure 5 26 Insert the attached pin through the handle and exten sion Figure 5 26 Attaching the extension handle When the exten 2 sion handle is attached the WAVE handheld system can be used as a manual T wrench E H Wachs Part No 11 MAN 02 Rev 1 0611 53 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual Torque is mea sured in the main handle of the WAVE handheld system When two people are operat ing the machine this reading is only half the total torque Putting the control unit in two person mode doubles the measured torque to accu rately display total torque being applied to the valve key Control unit screen showing two person mode The second operator should stand on t
54. ne person mode E H Wachs Part No 11 MAN 02 Rev 1 0611 45 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual WARNING The WAVE hand held system can produce up to 800 Ib ft 1085 N m of torque Make sure you stand so that the torque pulls the handle away from your body Always move to the other side of the machine before reversing the direction of operation If you do not know the rotation direc y tion of the valve see Logging an Unknown Valve Rotation Direction later in this section Performing the Valve Operation Before starting make sure the torque is set to the lowest set ting Be sure to read the Direction and Torque Control section in this chapter for instructions on machine control for the power version of your WAVE handheld system Zeroing the Valve Position 1 Stand on the correct side of the WAVE system for the direction you are turning the valve Refer to the Operator Position label on the handle Engage the power in the direction you are turning the valve If the valve does not move disengage power Switch position and apply power in the opposite direction If the valve does not move increase the torque and apply power again Continue this process increasing the torque and applying power in both directions until the valve stem breaks free When the valve starts turning reduce torque to the lowest setting that will
55. nue until the valve is completely closed without exceeding the maximum torque setting Switch sides and back the valve off 2 3 rotations E H Wachs Part No 11 MAN 02 Rev 1 0611 49 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual 2 3 rotations Figure 5 21 Turn the valve back up 2 3 rotations to clear loosened debris 10 Switch sides and drive the valve back to the end of travel Repeat the back and forth motion two more times to make sure all debris is cleared from the slides and the valve is fully seated at the end of travel 2 3 rotations End of travel Figure 5 22 Turn the valve up and down two times against the end of travel to fully seat it in the closed position Resetting the Valve travel in one direction press the RESET When you have driven the valve to the end of oe COUNT button 50 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions Start turning the valve back in the other direction It should operate freely Figure 5 23 Turn the valve continuously in the open ing direction 3 When you approach the opposite end of travel the torque may begin to increase If it exceeds the torque limit use the back and forth process to drive the valve to the end of travel Figure 5 24 If necessary turn the valve back and forth to loosen it as y
56. on 0 cece ccc 103 Ordering Replacement Parts ck Seek eee Se See bes ree heehee S E 103 Repair Information es Dos et Bout d V px eee Davee gad d donee Ole ae aS 103 Warranty Information 8 5 104 Return Goods Address 7 e xus x Y d Sess So doe x RM he EAE SO A NOR 104 E H Wachs Part No 11 MAN 02 Rev 1 0611 iii Contents WAVE Handheld Valve Exerciser User s Manual iv Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 1 About This Manual Chapter 1 About This Manual PURPOSE OF THIS MANUAL This manual explains how to operate and maintain your WAVE Wachs Automated Valve Equipment handheld valve exerciser It includes instructions for assembly set up operation and maintenance It also contains parts lists assembly diagrams and troubleshooting instructions to help you order replacement parts and perform user serviceable repairs Before operating your WAVE handheld unit you should read through this manual and become familiar with all instructions At a minimum make sure you read and under stand the following chapters e Chapter 1 About This Manual e Chapter 2 Safety e Chapter 3 Introduction to the WAVE Handheld e Chapter 5 Operating Instructions If you will be performing service or repairs make sure you read and understand these chapters e Chapter
57. opriate sized sleeve over the press fitting onto the top of the seal the sleeve down onto the seal with a hammer until the sleeve is flush with the machine surface Figure 7 5 Tap the seal into place with a hammer until the sleeve is flush against the housing PROBLEM The current torque reading on the WAVE control unit doesn t go to zero when you press the Reset Torque button E H Wachs Part No 11 MAN 02 Rev 1 0611 69 Chapter 7 Service and Repair WAVE Handheld Valve Exerciser User s Manual Data stored in the control unit will be y lost when you remove the battery Transfer any data you need to the VITALS data logger before turning off the control unit CAUSE The torque sensor is mis calibrated You can return the WAVE machine to the factory for calibration See Chapter 10 for ordering information ELECTRICAL PROBLEMS PROBLEM The control unit screen displays nonsense characters CAUSE The control unit may have lost battery power If you have valve operation data you want to save transfer it immediately to the VITALS data logger 1 Press and hold the NEW ACTIVITY button for two seconds The screen should return to normal 2 If pushing the NEW ACTIVITY button does not cor rect the problem power the control unit off and then power it on again PROBLEM Valve operation data is being lost before you can transfer it to the VITALS data logger CAUS
58. ou approach the end of travel 4 When you have reached the end of travel back the valve up 2 3 rotations and drive it to the end again Repeat this step two more times E H Wachs Part No 11 MAN 02 Rev 1 0611 51 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual End of travel 2 3 rotations Figure 5 25 Turn the valve up and down two times against the end of travel to fully seat it in the open position 5 Write down the total number of rotations or transfer the valve data to the VITALS data logger Logging an Unknown Valve Rotation Direction If you do not know the rotation direction for closing the valve use the following procedure to document the opera tion 1 Press the NEW ACTIVITY button and hold it x for two seconds until the rotation and torque reading reset to zero 2 Select a direction and apply torque at the lowest torque setting 3 If you feel resistance stop and reverse direction Ifnecessary increase by the torque by turning the torque knob clockwise one half turn If you feel resis tance reverse direction again and apply the same amount of torque 5 Continue this procedure reversing direction when you feel resistance until you get the valve turning freely in one direction 52 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions Tur
59. p on the end of the handle unscrews to charge the battery 3 Connect the charger cable to the battery charging con nector E H Wachs Part No 11 MAN 02 Rev 1 0611 19 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual If you do not have time for a full 2 charge you partially charge the battery without damaging it Figure 3 12 Charger plugged into the battery charg ing connector Note that the connector must be aligned correctly to line up the pins with the sockets Connect the power cable from the charger to the power source Figure 3 13 Plugging in the charger will start charg ing the battery Charging a fully drained battery takes about 2 4 hours The charger will automatically shut off when the bat tery is fully charged When you are finished charging remove the charger cable from the battery charging connector Replace the cap on the WAVE system s handle 20 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld Control Unit Memory Backup Battery A standard size 3 V watch battery CR1632 or equivalent maintains data in memory when the control unit is turned off This keeps your settings as well as the valve operation data from the most recent activity Replacement Procedure 1 If the control unit is on turn off power to it e On electr
60. pecification for maximum torque you can use this value for the torque limit To switch torque y units between lb ft and N m press the Reset Count and Zero Torque buttons together WARNING Stand so that the torque pulls the han dle away from your body Always move to the other side of the machine before reversing the direction of operation The WAVE con y trol unit will store all forward and reverse motion data The rotation counter displays absolute rotations from the starting point E H Wachs Part No 11 MAN 02 Rev 1 0611 47 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual This back and forth process allows water flow ing through the valve to clear away loosened debris 10 rotations Figure 5 17 Drive the valve about 10 rotations in the closing direction 7 Switch sides and apply power to turn the valve back in the other direction Turn it for 2 3 rotations 2 3 rotations Figure 5 18 Back the valve up 2 3 rotations Continue this back and forth procedure until you reach the end of travel 48 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 5 Operating Instructions 2 3 rotations 10 rotations Figure 5 19 Continue driving the valve down Turn 10 rotations in the closing direction then 2 3 in the opening direction Figure 5 20 Conti
61. r transfer it to your PC before removing the battery 3 Carefully remove the back cover and turn it over to Use a 5 64 hex access the circuit board inside the data logger The y wrench to turn the battery is in a socket mounted on the circuit board as Screws shown in Figure 3 21 Figure 3 21 The memory battery is in a socket on the circuit board E H Wachs Part No 11 MAN 02 Rev 1 0611 25 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual CAUTION Do not touch any other compo nents on the cir cuit board or use any metallic tools Use a standard CR1632 3 V or equivalent watch battery CAUTION Make sure you re install the gasket before replacing the cover A f A Using your fingernail or a non metallic tool remove the battery from the socket Figure 3 22 Remove the old battery from the socket Slide a new battery into the socket with the plus side up Figure 3 23 Slide the new battery into the socket with the plus side up Replace the back cover on the data logger and insert the screws 26 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld PACKAGING The WAVE handheld valve exerciser is shipped and stored in a custom steel case Figure 3 24 shows the WAVE system in the case with the extension handle Use the storage ca
62. replace them with the revised chap ters Current versions of E H Wachs Company manuals are also available in PDF for mat You can request an electronic copy of this manual by emailing customer service at sales wachsco com E H Wachs Part No 11 MAN 02 Rev 1 0611 Chapter 1 About This Manual WAVE Handheld Valve Exerciser User s Manual 4 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 2 Safety Chapter 2 Safety The E H Wachs Company takes great pride in designing and manufacturing safe high quality products We make user safety a high priority in the design of all our products Read this chapter carefully before operating your WAVE handheld valve exerciser It contains important safety instructions and recommendations OPERATOR SAFETY Follow these guidelines for safe operation of your WAVE handheld system READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin INSPECTMACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leak ing lubricant rusted components and any other physical conditions that may affect operation Properly maintain ing the machine can greatly decrease the chances for injury ALWAYS READ PLACARDS AND LABELS Make sure all placards labels and stickers are clearly legible and in good condition You can purchase replacem
63. rough five to ten rotations Then reverse the direction for two or three revolutions followed by up to ten more turns in the closing direction This procedure illustrated in Figure 3 1 should be repeated until the valve is fully closed 2 3 rotations 10 rotations v 10 rotations Figure 3 1 Closing a valve using a back and forth process to prevent jamming After the valve is reopened turn it in the closing direction one or two revolutions The next time the valve is operated the nut and stem will not be jammed against the bonnet and the valve will be free If the operator trying to close the valve turns it the wrong way a positive stop will occur after one or two turns The operator can then reverse direction to fully operate the valve The steady torque applied by the WAVE handheld system is less likely to damage valve components than turning the valve by hand With the optional VITALS data logger detailed information on torque and valve position can be stored for each valve that is exercised 10 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld MECHANICAL OVERVIEW Electric Drive Power head Lifting handle Electric motor Control unit Power cord Ground fault circuit interrupt GFCI Direction switch Power switch Figure 3 2 WAVE M handheld system mechanical components
64. s 28 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld Hydraulic Drive Torque Performance The torque performance in Table is based on hydraulic flow of 8 gpm at 1800 psi 30 Ipm at 124bar Ib ft N m RPM 100 136 24 200 271 22 300 407 20 400 542 17 500 678 10 600 813 700 949 800 1084 1 Table 3 WAVE M Hydraulic Power Handheld Torque Performance Shaded row is factory rated continuous load Pneumatic Drive Torque Performance The torque performance in Table 1 is based on hydraulic flow of 8 gpm at 1800 psi 30 Ipm at 124 Ib ft N m RPM 100 136 13 200 271 11 300 407 7 400 542 5 500 678 4 600 813 3 700 949 2 800 1084 1 Table 4 WAVETM Pneumatic Power Handheld Torque Performance Shaded row is factory rated continuous load E H Wachs Part No 11 MAN 02 Rev 1 0611 29 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual Physical Specifications Capacity Drive Power Requirements Peak Torque Motor Control Revolution Counter Torque Display Valve Operation Data Storage Pressure Gauge Finish Operates all gate valves 6 to 60 15 3 to 152 4 cm and other equipmen
65. se to transport your WAVE system Figure 3 24 WAVE handheld system in its storage case MACHINE SPECIFICATIONS Electric Drive Torque Performance The torque performance in Table 1 is for WAVE handheld systems equipped with 110 V electric power Table Figure 2 presents torque performance for systems with 220 V electric power E H Wachs Part No 11 MAN 02 Rev 1 0611 27 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser User s Manual High speed low torque Low speed high torque setting setting lb ft N m RPM AMPS RPM AMPS 100 136 10 8 6 6 4 200 271 8 8 6 5 6 300 407 7 11 4 7 375 509 6 12 8 500 678 5 15 4 10 600 813 3 6 12 700 949 3 12 5 800 1084 3 13 5 Table 1 WAVE 110 V Electric Power Handheld Torque Performance Shaded rows are factory rated continuous loads High speed low torque Low speed high torque setting setting lb ft N m RPM AMPS RPM AMPS 100 136 10 8 6 6 4 175 237 8 8 6 5 6 300 407 7 11 4 7 375 509 6 12 8 500 678 5 15 4 10 600 813 3 6 12 700 949 3 12 5 800 1084 3 13 5 Table 2 WAVE 220 V Electric Power Handheld Torque Performance Shaded rows are factory rated continuous load
66. t requir ing mechanized turning High durability bronze steel gear train Electric options for 110 V 60 Hz 110 V 50 Hz 220 V Hydraulic 8 30 lpm hydraulic flow 1800 psi 124 bar Pneumatic 90 psi 6 2 bar air supply at 60 cfm 1 700 Ipm 800 Ib ft 1084 N m Adjustable torque setting valve from 0 to 800 Ib ft with pressure gauge and elec tronic torque indicator Reversing valve spring loaded self cen tering automatic stop after release Built in electronic counter display counts in 1 10 revolution increments forward and reverse automatically Electronic keypad button reset Electronic readout of current and maxi mum torque with torque limit display and warning indicator Storage of torque values for 5000 rotation positions in increments of 1 10 rotation Push button memory reset 0 to 800 Ib ft Powder coated casting nickel plated handles and accessories 30 Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 3 Introduction to WAVE Handheld Valve Key Size Socket Dimensions Weight Storage Case Accessories Standard Optional 1 square solid 2 54 cm 2 square AWWA standard 5 cm Length 40 102 cm Width 7 3 4 20 cm Height 7 1 4 18 cm 36 lbs 16 kg Electric 40 Ibs 18 kg Hydraulic 37 lbs 17 kg Pneumatic Length 42 107 cm Width 11 1 2 29 cm Hei
67. the valve position E H Wachs Part No 11 MAN 02 Rev 1 0611 61 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual Remarks can be defined using the VITALS valve performance analysis soft ware and downloaded to the data logger A v Use the up and down arrows to highlight remarks CG Use the right arrow to select the highlighted remark A separate cable Wach part no 17 2 234 00 to connect GPS receiver to the data logger You can turn off the READING GPS 2 feature Press the MENU button and scroll down to the ENABLE GPS command press NEXT and then select the OFF option 14 L5 ESO Figure 5 41 VALVE POSITION screen The REMARKS screen appears Use the up and down arrows to highlight remarks Press e the right arrow button to select the currently highlighted remark You can select up to 10 remarks for an activity Selected remarks are indicated with an asterisk When you are finished selecting remarks push the NEXT button to continue Figure 5 42 REMARKS screen Selected remarks are indicated by asterisks The READING GPS screen appears If you are storing GPS data and have not yet connected your GPS receiver to the data logger connect it now If you are not storing GPS data press the NEXT button and skip to step 17 62 Part No 11 MAN 02 Rev 1 0611 E H Wachs
68. the WAVE sys tem 2 Turn on the WAVE control unit by pushing the power button on its side Figure 5 8 The start up screen will appear and then the data display screen will indicate that the control unit is ready US J Figure 5 9 Press the power button on the control unit to turn it on Direction and Torque Control Electric Drive Set the direction of rotation using the direction control switch on the handle Push the switch forward toward the control unit to set the rotation in the right hand direction Push the switch backward to set the rotation in the left hand direction You should use an amp in line oiling sys tem with the pneu matic WAVE handheld system Use an antifreeze oil when operating with continu ous load and high torque E H Wachs Part No 11 MAN 02 Rev 1 0611 41 Chapter 5 Operating Instructions WAVE Handheld Valve Exerciser User s Manual You may have to engage the power 2 switch when changing the speed switch setting Press the power switch briefly while moving the speed switch into the other position The switch is seated when the screw head retracts into the switch forward reverse Figure 5 10 Set the direction of rotation using the direction control switch The forward position sets the rotation in the right hand direction The reverse posi tion sets the rotation in the left hand direction 2 There are two speed torque
69. troduction to the WAVE Handheld Valve Exerciser Read this chapter carefully to become familiar with the components of your WAVE handheld valve exerciser For convenient access to a power source the WAVE handheld valve exerciser is available with three different motor drives electric hydraulic and compressed air This manual provides instructions for all three power versions USAGE AND APPLICATIONS The WAVE line of handheld valve exercisers redefines portable valve exercising and testing This versatile unit is light enough to be used by one operator yet is rugged enough to operate valves up to 60 inches It s designed for efficient valve exercising and testing and is perfect for hard to reach valves The WAVE handheld systems provide you with the fol lowing capabilities Operation of 3 times more valves per day in your valve exercising program e Readiness for fast emergency shut offs e Elimination of operator fatigue and back injury e Reduced valve damage during exercising Operation of valves where access is limited e Easy storage and transport Easy use by one operator In This Chapter USAGE AND APPLICATIONS MECHANICAL OVERVIEW SAFETY LABELING CONTROL UNIT AND KEYPAD VITALSTM DATA LOGGER BATTERY POWERED COMPONENTS PACKAGING MACHINE SPECIFICATIONS E H Wachs Part No 11 MAN 02 Rev 1 0611 Chapter 3 Introduction to WAVE Handheld WAVE Handheld Valve Exerciser
70. ymbol indicates a safety warning A warning means that there is a risk of operator injury CAUTION This symbol indicates a caution alert A caution means that there is a risk of dam age to the equipment or to the component being serviced Part No 11 MAN 02 Rev 1 0611 E H Wachs WAVE Handheld Valve Exerciser User s Manual Chapter 1 About This Manual NOTE This symbol indicates a user notice Notices provide additional information to supplement the instructions or tips for easier operation MANUAL UPDATES AND REVISION TRACKING Occasionally we will update manuals with improved opera tion or maintenance procedures or with corrections if nec essary Revised chapters will be available for customers If you receive revised chapters for your manual remove the old chapters from your binder and replace them with the new chapters When a manual is revised we will update the revision his tory on the title page and at the bottom of the pages in the revised chapters It is important to put the current title page with the revision history in your manual This will help you make sure you have all current information You may have factory service or upgrades performed on your WAVE handheld exerciser If this service changes any technical data or operation and maintenance proce dures we will include revised sections of the manual when we return the equipment to you Remove the old chapters from your manual and

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