Wachs ERV-750 User manual

ERV-750 Extended Reach
Valve Operator
User’s Manual
Copyright © 2009 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.
E.H. Wachs
600 Knightsbridge Parkway
Lincolnshire, IL 60069
www.ehwachs.com
E.H. Wachs Part No. 79-MAN-01
Rev. 3-0409, April 2009
Revision History:
Original January 2008
Rev. 1 February 2008
Rev. 2 December 2008
Rev. 3 April 2009

ERV-750 Extended Reach Valve Operator
Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs

Table of Contents
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 i
Table of Contents
Chapter 1: About the ERV-750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
How to Use The Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Symbols and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Manual Updates and Revision Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Equipment Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connecting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installing the ERV-750 on Existing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation Troubleshooting Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 2: Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Protective Equipment Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 3: Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Setting Up the Valve Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Performing the Valve Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Starting the Vitals Data Logging Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Running the Wachs Controller Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Chapter 4: Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 5: Parts List and Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Ordering Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Ordering Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Return Goods Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Layout Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

ERV-750 Extended Reach Valve Operator
ii Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
Parts Lists and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mechanical Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installation Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chapter 1, About the ERV-750
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 1
Chapter 1
About the ERV-750
PURPOSE OF THIS MANUAL
This manual explains how to operate and maintain the
ERV-750 extended reach valve operator. It includes instruc-
tions for set-up, operation, and maintenance. It also con-
tains parts lists and diagrams to help you order replacement
parts and perform user-serviceable repairs.
HOW TO USE THE MANUAL
Throughoutthismanual,refer
to this column for warnings,
cautions, and notices with
supplementary information.
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. Thislarge 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.
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.
In This Chapter
PURPOSE OF THIS MANUAL
HOW TO USE THE MANUAL
SYMBOLS AND WARNINGS
MANUAL UPDATES AND
REVISION TRACKING
EQUIPMENT DESCRIPTION
INSTALLING THE ERV-750 ON
EXISTING EQUIPMENT

ERV-750 Extended Reach Valve Operator
2 Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
Make sure you understand what each symbol means, and
follow all instructions for cautions and warnings.
A WARNING alert with the
safety alert symbol indicates
a potentially hazardous situa-
tion that could result in seri-
ous injury or death.
A CAUTION alert with the
safety alert symbol indicates
a potentially hazardous situa-
tion that could result in
minor or moderate injury.
A CAUTION alert with the
damage alert symbol indi-
cates a situation that will
result in damage to the
equipment.
An IMPORTANT alert with
the damage alert symbol indi-
cates a situation that may
result in damage to the
equipment.
A NOTE provides supple-
mentary information or oper-
ating tips.
WARNING
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 avoid possible
injury or death.
CAUTION
CAUTION
This is the equipment damage alert
symbol. It is used to alert you to poten-
tial equipment damage situations.
Obey all messages that follow this sym-
bol to avoid damaging the equipment or
workpiece on which it is operating.
IMPORTANT
NOTE
NOTE
This symbol indicates a user note. Notes
provide additional information to supple-
ment the instructions, or tips for easier
operation.

Chapter 1, About the ERV-750: Manual Updates and Revision Tracking
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 3
MANUAL UPDATES AND REVISION TRACKING
Current versions of E.H.
Wachs manuals are also
available in PDF format. You
can request an electronic
copy of this manual by email-
ing customer service at
[email protected].
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 ERV-750 is an automated, medium-duty valve operator
mounted on an extension arm to reach valves up to 13 feet
from the pedestal mount. With the ERV-750 mounted on
your truck or utility trailer, you can reach many valves when
parked curbside. It operates on hydraulic power, using a
ruggedized, computer-based controller that can store and
transfer valve operation data.
The standard configuration is provided on a Wachs Swivel-
Vac heavy-duty trailer; the system’s components can also be
mounted on a truck or pickup bed with the optional installa-
tion kit.
Specifications
• Operates all valves 6”-60”
• 750 lb-ft maximum torque
• 0-30 rpm
• 13 ft arm (on Swivel Vac trailer, reaches 11 ft to the curb
side and 9 ft to the driver side) with locking extension
• swivel mounting pedestal with position lock
• microprocessor control system
• Vitals Recon controller, a Windows CE-based handheld
pendant with operating and data logging software
• 4-9 ft telescoping valve key (3 ft extensions available)

ERV-750 Extended Reach Valve Operator
4 Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
System Components
The following figures illustrate the components of the ERV-
750.
Figure 1-1. The photo shows the ERV-750 mounted
on the Wachs Swivel Vac trailer.
Figure 1-2. The photo illustrates the components of
the ERV-750.
ERV-750
Pedestal
mount
Upper
arm
Lower
arm
Telescoping
extension arm
Head Valve key
adapter

Chapter 1, About the ERV-750: Equipment Description
E.H. Wachs Part No. 79-MAN-01, Rev. 3-0409 5
Figure 1-3. The photo illustrates the ERV-750 head.
Figure 1-4. The ERV-750 controller has a touch-
screen for operation.
Hydraulic
motor Control
pendant
Positioning
handle
Control
connector

Torque—Displays current
operating torque. Touch to
change torque limit
Highest—Displays aximum
torque during current activity
Count—Displays valve rota-
tions during current activity.
START/STOP—Touch to
start or stop the valve exer-
ciser. (Displays STOP if the
exerciser is operating.)
Back—Touch to return to
Vitals Mobile program.
Reset—Touch to start a new
activity.
Limit—Displays current torque
limit. Touch to change torque limit.
Direction—Displays current turn-
ing direction. Touch to set turning
direction.
Mode—Displays current operat-
ing mode (Exercise or Manual).
Touch to change mode.
Jog LH—Touch and hold to jog
left-hand (counter-clockwise).
Jog RH—Touch and hold to jog
right-hand (clockwise).
Settings—Touch to change valve
operating settings.
Waiting to connect—Displays
current operating status (reads
Connected to ERV-750 when
startup is complete).

ERV-750 Extended Reach Valve Operator
6 Part No. 79-MAN-01, Rev. 3-0409 E.H. Wachs
Operation Overview
This section briefly describes the ERV-750 controls. See
Chapter 3 for detailed operating instructions.
1. For an ERV-750 installed on the Swivel Vac trailer,
turn on power to the unit using the switch on the con-
trol box. The engine must be running to power up the
ERV.
Figure 1-5. Push the power switch on the control box
down to turn on power to the ERV-750.
2. When power is enabled to the ERV, brakes in both
swivel joints of the arm lock the arm in its current
location. To move the arm, hold down the brake
release button on the positioning handle and move the
arm to its desired location.