Manual - EH Wachs
Contents
1. 01 dw 00 0 0 11 9 00 44059 ONIN 00 94059 4 JAINA Y31dNOD 00 77 1 99 CONI lv72g 00 87 1 99 JIANYH 90 010 01N ALO NOU A 20 JIIWNAN Lavd WALI See facing page for identification of parts E H Wachs Part No U10 010 MAN Rev 0 0310 26 Chapter 5 Parts Lists and Ordering Drawings and Parts Lists ASSEMBLY NO U10 10 00 PRODUCTION DATE APRIL 2010 E H WACHS UTILITY PRODUCTS PROJECT No U10 10 HIGH SPEED HAND HELD VALVE OPERATOR E H Wachs Part No U10 010 MAN Rev 0 0310 27 High Speed Handheld Valve Operator ORDERING INFORMATION To place an order request service or get more detailed information on any E H Wachs products call us at one of the following numbers U S Toll Free 866 392 1060 US Local 815 943 4785 Ordering Replacement Parts When ordering parts refer to the parts list in this chapter Please provide the part description and part number for all parts you are ordering Always note your machine model number when 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 A brief description of the problem or work to be done Before2. positions for low speed turtle neutral 0 and high speed rabbit The switch is shown at low speed setting Direction of Rotation The valve operator is reversible Figure 1 3 shows the direc tion of rotation for the indicated motor direction To reverse direction slide the motor direction switch to the opposite position Figure 1 3 The photo illustrates the direction of rota tion for indicated motor direction E H Wachs Part No U10 010 MAN Rev 0 0310 High Speed Handheld Valve Operator Telescoping Valve Key A telescoping valve key allows you to reach valves at differ ent depths and to adjust the length of the key to position the valve operator at the desired height You can adjust the key from 4 to 9 feet in length and add an extension for a maxi mum of 12 feet Figure 1 4 shows the valve key Valve operator shaft Spring locking pin Valve socket Figure 1 4 The telescoping valve key can be extended by pressing in the locking pin and pulling out the valve socket shaft 6 Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 2 Safety Chapter 2 Safety E H Wachs takes great pride in designing and manufactur ing safe high quality products We make user safety a top priority in the design of all our products Read this chapter carefully before operating the valve oper ator It contains important safety instructions and recom mendations OPERATOR SAFETY Follow these guideli
3. we perform any repair we will estimate the work and inform you of the cost and time required to complete it Warranty Information Enclosed with the manual is a warranty card Please fill out the registration card and return to E H Wachs 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 Utility Products Division 455 Comanche Circle Harvard Illinois 60033 USA 28 Part No U10 010 MAN Rev 0 0310 E H Wachs E H Wachs 455 Comanche Circle Harvard IL 60033 815 943 4785 www wachsco com
4. 0 0310 15 High Speed Handheld Valve Operator 16 Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 4 Maintenance Chapter 4 Maintenance In This Chapter _ LUBRICATION LUBRICATION REPAIR There is one grease fitting on the valve operator head Apply grease every few hours of operation Figure 4 1 Apply grease through the grease fitting on the head REPAIR The revolution counter display and sensors can be replaced in the event they become damaged or stop working Before performing any service make sure the valve opera tor is unplugged from the electrical source E H Wachs Part No U10 010 MAN Rev 0 0310 17 High Speed Handheld Valve Operator Replacing the Counter You do not need to remove the handle to replace the coun ter 1 Remove the 2 screws holding the counter in the head Figure 4 2 Remove the 2 screws to take the counter out of the head 2 Pull the counter out gently Pull the electrical connec tor off the back of the counter Dn i Figure 4 3 Pull the connector from the back of the counter 3 Plug the connector into the back of the new counter The connector can only be connected in one orienta tion 18 Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 4 Maintenance Repair E Figure 4 4 Plug the connector into the pin block on the back of the counter 4 Carefully tuck the wires bac
5. 50 lb ft Maximum speed 40 rpm Power 110 V 60 Hz AC requires a 15 amp or 3500 W generator Rev counters Built in digital counter display with 1 revolution increments and push button reset Valve key size 1 2 54 cm square solid Socket 2 5 1 cm square AWWA standard Dimensions Length 40 102 cm Width 14 36 cm Height 3 5 9 cm Weight 31 Ib 14 kg Options Telescoping valve key up to 8 ft long 2 square AWWA standard ductile iron socket stop collar 15 16 drive socket System Components Figure 1 1 illustrate the components of the valve operator E H Wachs Part No U10 010 MAN Rev 0 0310 3 High Speed Handheld Valve Operator Rotating head Counter Drive adapter Electric drive Figure 1 1 The photo illustrates the major compo nents of the valve operator Motor Controls Use the electric drive controls to set the speed direction and the gear ratio The gear ratio switch has settings for high range low range and neutral The speed dial lets you vary the speed within the current range while running the valve operator Gear ratio switch Speed dial Use the speed control dial and the gear ratio switch to set the electric drive speed 4 Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 1 About the High Speed Valve Operator Equipment Description Low speed range Neutral High speed range Position indicator Figure 1 2 The gear ratio switch has
6. High Speed Handheld Valve Operator User s Manual E H Wachs 455 Comanche Circle Harvard IL 60033 www wachsco com E H Wachs Part No U10 010 MAN Rev 0 0310 March 2010 Revision History Original March 2010 Copyright 2010 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 High Speed Handheld Valve Operator Part No U10 010 MAN Rev 0 0310 E H Wachs Table of Contents Table of Contents Chapter 1 About the High Speed Valve Operator 1 Purpose ceed oes EE EH E EEN eis tence Sess 1 How te Use The Manual tege bus Seach E gone clea Gk eS gS eRe 1 Symbols and Warnings A dc ere d Saeed Rae we aw Abed eu be anne ede ae 2 Manual Updates and Revision Tracking de eege ee Ser e EN Le 2 Equipment Description ENEE cide 2 EEN Ee Beet Ae deer oh ard whe a dae e Ba RE ap pee ace 3 System Components Sis o E A gen dds 3 Motor Wee 4 IR Ee E e EE 5 Telescoping Valve ett Bie caw 6 Chapter 2 Safety EE 7 Operator Safety Eege ENEE dee ee A 7 GETRENNT SSAA amp Protective Equipment Requirements 9 Chapter 3 Operating Instruction 11 Site Preparat
7. arts lists and diagrams to help you order replacement parts and perform user serviceable repairs 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 the equipment 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 the equipment The narrower column on the outside contains additional information such as warnings special notes and defini tions Refer to it for safety notes and other information In This Chapter PURPOSE OF THIS MANUAL How TO USE THE MANUAL SYMBOLS AND WARNINGS MANUAL UPDATES AND REVISION TRACKING EQUIPMENT DESCRIPTION Throughout this manual refer to this column for warnings cautions and notices with supplementary information E H Wachs Part No U10 010 MAN Rev 0 0310 High Speed Handheld Valve Operator 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 This is the safety alert symbol It is used to alert you to potential personal injury hazards Obey all safety messages that follow this symbol to avo
8. clamping pads AN 6 Identify sensor position The sensor marked with a red band senses rotation and must be placed in the proper bore as indicated in Figures 4 10 amp 4 11 Figure 4 9 The sensors and wires to the counters are a single assembly E H Wachs Part No U10 010 MAN Rev 0 0310 21 High Speed Handheld Valve Operator 7 Replace the new sensors into the holes to the cavity Ensure proper position of marked sensor Figure 4 10 Insert the two sensors into the holes leading into the machine shaft cavity 8 Slide sensors in until both contact the hub Lightly tighten set screws Sensors must be able to move with minimal force but not freely Sensor with marked lead Figure 4 11 Cross section of assembly showing sen sors against magnet retaining sleeve Rotate the drive hub two full revolutions 10 Reconnect the counter and verify operation 22 Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 4 Maintenance Repair 11 Once proper operation is confirmed tighten set screws Do not exceed 2 in Ibs or damage to the sen sors may result 4 Figure 4 12 Tighten the 2 set screws to secure the sensors in place 12 Install counter 13 Re attach the head to the handle E H Wachs Part No U10 010 MAN Rev 0 0310 23 High Speed Handheld Valve Operator 24 Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 5 Parts Lists and Orderin
9. g Drawings and Parts Lists Chapter 5 Parts Lists and Ordering DRAWINGS AND PARTS LISTS The drawings and parts list on the following pages illustrate the components of the valve operator assembly In This Chapter DRAWINGS AND PARTS LISTS ORDERING INFORMATION E H Wachs Part No U10 010 MAN Rev 0 0310 25 High Speed Handheld Valve Operator Bill of materials for the high speed valve operator 910 LENOVW 4 3319 1150105011 Ir ONIdWV19 YOSNAS 10 6 1 11 DE L AISWISSY 405395 210 010 011 6C ATaWASSV YOLOW 02 010 011 8 X 9 SOHA 0 0 06 10 SLX 91 SZE 10 10 06 9 GS X CE 8 SHOS XH 0 0 06 Cl 001 X 8L 9L S SOHS 01 090 06 44 LHOIVALS ANN 87 1 ONIL ASVWAID 0 004 06 T L X ZE 8 40585 0 70 06 CC 13NDYW 00 920 9 12 YALNNOD 00 00 9 0 avid ONISNOH 00 4059 l ONIN 00 6 0 9 81 ONIdN79 00 070 9S Zl AVAD ONISNOH S0 010 01N 91 IN3WG 13M 01 010 01 Sl NOINId AVA 00 600 9S vl dc 0 010 01 l AINANL JAYA 93345 HOIH 10 010 01 Cl Widva 0 010 01N LL FIGNVH did JIJINA 00 90 11 01 INdINO AYVIANV 1d 00 01 11 6 AaVISNV 1d 00 02 9S 8 13S AWAD YAS OO COC 9G
10. id possible injury or death 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 manuals will be available for customers When a manual is revised we will update the revision his tory on the title page and at the bottom of the pages You may have factory service or upgrades performed on the equipment If this service changes any technical data or operation and maintenance procedures we will include a revised manual when we return the equipment to you EQUIPMENT DESCRIPTION The high speed valve operator is designed to turn valves from 6 to 60 at a higher speed than conventional valve Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 1 About the High Speed Valve Operator Equipment Description exercisers This is advantageous in situations where you need to quickly open or close a valve without needing to run a high torque exercising operation The machine operates on 110 VAC power and utilizes a reversible motor to simplify valve excercising operations and to reduce operator effort System Specifications Application Operates all gate valves 6 to 60 152 mm to 1524 mm and other equipment requiring mechanized turning Maximum torque 3
11. ion 4 45400 a wa AEN ea EE bg ed oa Re ee ae 11 O pee tac ata perce dco a ad E EE 11 Operation SERA SR EE ie a A 13 Operator Position E eae 13 Luring the Valye rne Ee EE EE ae 13 Chapter 4 Maintenance dss eS Seeks ee he ees ONES Ee KEE NEE 17 EE 17 Tae E sa EE geo E 17 Replacing eS SRN SK EE 18 Replacing the Sensors UE ESA TA DEE REENEN NK e Ne 19 Chapter 5 Parts Lists and Ordering 25 Drawings and Parts Isists ts ei aE 25 Ord rine Informati n Bad te ngs os ws erte e ere 28 Ordering Replacement Parts EE 28 Repair Information 4 09 see ye A ee EE 28 Warranty sel 28 Return Goods Address dad Ree eR ew UA Lae de 28 E H Wachs Part No U10 010 MAN Rev 0 0310 i High Speed Handheld Valve Operator ii Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 1 About the High Speed Valve Operator Chapter 1 About the High Speed Valve Operator PURPOSE OF THIS MANUAL This manual explains how to operate and maintain the high speed handheld valve operator It includes instructions for set up operation and maintenance It also contains p
12. jury hazard Z WARNING This safety alert indicates a potentially hazardous situation that if not avoided could result in death or serious injury Z CAUTION This safety alert with the personal injury hazard symbol indicates a potentially hazardous situation that if not avoided could result in minor or moderate injury NOTICE This alert indicates a situation that if not avoided will result in damage to the equipment Part No U10 010 MAN Rev 0 0310 E H Wachs Safety Operator Safety IMPORTANT This alert indicates a situation that if not avoided may result in damage to the equipment 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 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 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 i
13. just the length of the valve key Insert the valve key socket onto the drive nut on the valve Check that the top of the key is at the correct height Figure 3 2 Put the socket onto the valve nut Place the valve operator on the valve key Orient the machine correctly for the direction you are turning the valve Slide the head of the machine down onto the shoulder of the key shaft 12 Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 3 Operating Instructions Operation Figure 3 3 The valve operator rests on the shoulder at the top of the key shaft OPERATION Operator Position For safe operation you should stand at the end of the machine with the electric drive Hold the handle of the machine with one hand and operate the electric drive switch with the other hand The machine can be operated by two people One operator should stand at each end out of the way of the handle s rotation Turning the Valve 1 Plugin the valve operator power cord 2 Press the counter button to reset the counter to 0 3 Set the speed dial to A the slowest setting to start WARNING Cl The valve operator can produce up to 350 lb ft 475 N m of torque To avoid possible injury stand at the end of the machine instead of beside it where the handle can rotate into you NOTE Start with Gm the gear ratio switch in the low range E H Wachs Part No U10 010 MAN Rev 0 0310 High S
14. k into the head and put the new counter in 5 Putin the 2 screws and tighten them snugly Replacing the Sensors If the counter is working but is not incrementing as the valve operator turns the counter sensors may be malfunc tioning You will have to remove the handle from the head to replace the sensors 1 Remove the 8 screws that hold the handle to the head and remove the handle Figure 4 5 Remove the 8 screws holding the handle to the head assembly E H Wachs Part No U10 010 MAN Rev 0 0310 High Speed Handheld Valve Operator 2 Remove and unplug the counter as described in the previous section 3 Place the head assembly on a suitable work surface with the set screw holes on top Loosen the two set screws holding the sensors Figure 4 6 Loosen the 2 screws holding in the sen Sors 4 Remove the sensors by pulling them out of the machine shaft cavity The wires connector and sen sors are a single assembly Figure 4 7 Remove the sensors 20 Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 4 Maintenance Repair 5 Remove the set screws and verify clamping pads in place These small rubber pads distribute the clamp ing force of the screw to prevent damage to the sensor Pads should stay in the set screw hole and block sight of the sensor bore CS Set Screws 4 0 is Figure 4 8 Verify pad placement there is no need to remove the
15. ncrease 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 512 6 Hearing Protectors E H Wachs Part No U10 010 MAN Rev 0 0310 High Speed Handheld Valve Operator 10 Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 3 Operating Instructions Chapter 3 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 and that you are not standing in water when plug ging in or operating the machine Keep vehicles and any other equipment far enough away so that the handle of the valve operator can rotate around the valve key without obstruction SET UP 1 Adjust the telescoping valve key to the appropriate length by pushing in the locking pin and pulling out the socket shaft If necessary add the extension to lengthen the key In This Chapter SITE PREPARATION SET UP OPERATION The key should be Gm adjusted so that the valve operator is approximately waist to chest high on the user E H Wachs Part No U10 010 MAN Rev 0 0310 High Speed Handheld Valve Operator Figure 3 1 Press in the locking pin to ad
16. nes for safe operation of the equip ment e READ THE OPERATING MANUAL Make sure you understand all setup and operating instructions before you begin o INSPECT MACHINE AND ACCESSORIES Before starting the machine look for loose bolts or nuts leaking lubricant rusted components and any other physical conditions that may affect operation Properly maintaining the machine can greatly decrease the chances for injury e ALWAYS READ PLACARDS AND LABELS Make sure all placards labels and stickers are clearly legible and in good condition You can purchase replacement labels from E H Wachs KEEP CLEAR OF MOVING PARTS Keep hands arms and fingers clear of all rotating or moving parts In This Chapter OPERATOR SAFETY Look for this sym A bol throughout the manual It indicates a personal injury hazard E H Wachs Part No U10 010 MAN Rev 0 0310 High Speed Handheld Valve Operator 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 e 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 Safety Symbols A This icon is displayed with any safety alert that indicates a personal in
17. peed Handheld Valve Operator lt n D igure 3 4 Start with the speed dial set to the lowest speed A Engage the electric drive by squeezing the power switch on the drive motor Run the valve operator for 2 3 revolutions to make sure you are turning the valve in the free direction If you reach the end of travel release the power switch and reverse the motor direction When you have verified the valve direction turn the speed dial to set the desired speed Figure 3 5 Turn the speed dial to increase the speed To change between high and low gear ratios release the power switch and turn the gear ratio switch A rab bit icon indicates high speed range a turtle indicates low speed range The switch also has a neutral posi tion indicated by a 0 14 Part No U10 010 MAN Rev 0 0310 E H Wachs Chapter 3 Operating Instructions Operation Figure 3 6 Turn the gear ratio switch to the speed range desired If you are turning the valve to a specified position watch the revolution counter and stop when you have reached the desired number of turns 9 Tum the valve until you reach the desired position or the end of travel Release the power switch 10 If you are logging valve information write down the direction and number of turns to reach the end of travel 11 To reverse the valve reverse the motordirection and repeat this procedure E H Wachs Part No U10 010 MAN Rev
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