OPERATION and MAINTENANCE MANUAL

WAV
WALL PANEL MACHINE

www.NewTechMachinery.com
 TABLE OF CONTENTS
CHAPTER 1…….... SPECIFICATIONS ..........................................................................................1
CHAPTER 2…........ PRECAUTIONS ..............................................................................................2
CHAPTER 3………. MACHINE ORIENTATION ...........................................................................3
CHAPTER 4………. GENERAL MAINENANCE ...........................................................................5
Recommended Lubricants and Fluids ......................................................6
CHAPTER 5………. ELECTRICAL CONTROLS AND OPERATION ..........................................9
For Models with an Electric Motor or Both Gas and Electric Motors.....9
For Models with a Gas Engine Only......................................................13
CHAPTER 6………. REEL STANDS, REELS AND EXPANDABLE ARBORS .........................19
CHAPTER 7………. HYDRAULIC SYSTEMS .............................................................................26
Maintenance ...........................................................................................26
Hydraulic Fluid Troubleshooting...........................................................26
Changing Hydraulic Fluid and Filter .....................................................26
CHAPTER 8………. DRIVE SYSTEM ...........................................................................................30
CHAPTER 9……… SHEAR ASSEMBLY.....................................................................................34
CHAPTER 10……. WIDTH ADJUSTMENT ...............................................................................36
CHAPTER 11……... ENTRY DRUM ASSEMBLY .......................................................................39
CHAPTER 12……. PROFILE ADJUSTMENTS ..........................................................................41
CHAPTER 13……. USING UNDERSIZED COIL .......................................................................48
CHAPTER 14……... ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS ......................50
CHAPTER 15……. RUN OUT TABLES AND REMOTE LIMIT SWITCH ...............................53
CHAPTER 16…… TROUBLESHOOTING .................................................................................54
APPENDIX A……. ELECTRICAL SCHEMATICS .................................................................. A-1

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 LIST OF FIGURES

Figure 1: Machine Orientation ............................................................................................................ 3

Figure 2: Mounting Foot Detail .......................................................................................................... 4
Figure 3: Entry Guide ......................................................................................................................... 7
Figure 4: Acme Shafts and Width Adjustment ................................................................................... 8
Figure 5: Main Control Box Fuse ..................................................................................................... 10
Figure 6: Controls Gas/Electric ......................................................................................................... 11
Figure 7: VFD Enclosure ................................................................................................................... 12
Figure 8: Controls Gas Only .............................................................................................................. 16
Figure 9: Main Control Cable ........................................................................................................... 17
Figure 10: Run Out Table and Remote Limit Switch ....................................................................... 18
Figure 11: Expandable Arbor Set-Up ............................................................................................... 20
Figure 12: Expandable Reel Assembly ............................................................................................. 22
Figure 13: Trim Material ................................................................................................................... 24
Figure 14: Material Routing.............................................................................................................. 25
Figure 15: Hydraulic System – Overview ........................................................................................ 27
Figure 16: Hydraulic System – Details ............................................................................................. 28
Figure 17: Hydraulic Fluid Level ..................................................................................................... 29
Figure 18: Drive Roll Assembly View ............................................................................................. 31
Figure 19: Gears and Shafts .............................................................................................................. 32
Figure 20: Chains Upper and Lower ................................................................................................. 33
Figure 21: Entry/Exit Views ............................................................................................................. 35
Figure 22: Width Adjustment ............................................................................................................ 37
Figure 23: Tooling Rail Adjustment Handle .................................................................................... 38
Figure 24: Disengaged ...................................................................................................................... 38
Figure 25: Engaged ........................................................................................................................... 38
Figure 26: Entry Drum ...................................................................................................................... 39
Figure 27: Entry Drum Upper/Lower Position .................................................................................. 40
Figure 28: Eccentric Shafts ............................................................................................................... 41
Figure 29: Adjusting Eccentric Shafts .............................................................................................. 42
Figure 30: Eccentric Shaft Proper Adjustment ................................................................................. 42
Figure 31: Eccentric Shaft Too Loose .............................................................................................. 43
Figure 32: Eccentric Shaft Too Tight ............................................................................................... 43
Figure 33: Adjusting Station R-6 ....................................................................................................... 44
Figure 34: Adjusting Station R-10 ..................................................................................................... 44
Figure 35: Adjusting Station R-15 ..................................................................................................... 45
Figure 36: Adjusting Station L-14 ..................................................................................................... 45
Figure 37: Camber Adjustment - Uphill/Downhill ........................................................................... 46
Figure 38: Camber Adjustment ......................................................................................................... 47
Figure 39: Entry Guide Shoe and Lock Down Handle ..................................................................... 48
Figure 40: Shim Placement ............................................................................................................... 49
Figure 41: Wav Center Roller System .............................................................................................. 50
Figure 42: Wav Left and Right Roller System ................................................................................. 51
Figure 43: Wav Panel Profile............................................................................................................ 52
Figure 44: Run Out Tables ................................................................................................................ 53
Figure 45: Bottom of Stroke Limit Switch ....................................................................................... 54
Figure 46: Limit Switch Adjustment ................................................................................................ 56

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 CHAPTER 1
WAV SPECIFICATIONS

SPECIFICATIONS
WAV Dimensions: Length-22’ 8” (6.7m)
Width-5’ 1” (1.5m)
Height-4’ 5” (1.2m) w/Over Head Rack
2’ 7” (.61m) w/o Over Head Rack
Weight-5000 lbs. (2272.7kg)

WAV on Trailer: Length-27’ 10” (8.2m)

Width-7’ 4” (2.1m)
Height-6’ 7” (1.83m) with reel
Weight-8700 lbs. (3954.6kg)

Speed: 150 ft./min. Electric ( 45.7m/min.)

75 ft./min. Gas (22.9 m/min.)

Drive: Hydraulic via chain, sprocket and gear using 24 polyurethane drive
rollers.

Shear: Hydraulically Powered, hardened tool steel dies and blades w/Panel
Recognition Proximity Sensor

Hydraulic Fluid: 24 Gallons - 32AW

Coil Width: 24”

Materials Formed: Painted Steel 24ga. to 22ga. (.3mm to .8mm)

Painted, Galvanized, Aluminized

Controls: Computer Batch and Length Control

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 CHAPTER 2
PRECAUTIONS

PRECAUTIONS
1. Make sure the operator of the machine has read and understands this manual in its
entirety before attempting to operate this equipment.

2. ALWAYS keep covers, guards and lids mounted to machine during operation.

3. OBSERVE and OBEY all safety and warning signs affixed to the machine.

4. ALWAYS adhere to and follow all local and national safety codes concerning the loading
and un-loading of reeled coils.

5. USE ONLY properly rated devices for lifting reeled coils into or out of the reel stand
assembly.

6. DO NOT wear loose clothing, jewelry etc. that could become entangled in the moving
parts of the machine when operating.

7. STOP THE MACHINE and disconnect the power before attempting to make any
adjustments, perform any maintenance or changeover procedures.

8. AVOID storing the machine outdoors for long periods of time. Cover with a tarp but
provide good ventilation to prevent condensation and rust.

9. DO NOT USE SOLVENTS TO CLEAN DRIVE ROLLERS!

10. ALWAYS EMPTY MACHINE OF MATERIAL BEFORE TRANSPORT AND

STORAGE.

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 CHAPTER 3
MACHINE ORIENTATION

MACHINE ORIENTATION

Figure 1: Machine Orientation

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 CHAPTER 3
MACHINE ORIENTATION

Figure 2: Mounting Foot Detail

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 CHAPTER 4
GENERAL MAINTENANCE

GENERAL MAINENANCE
1. Always keep covers on during operation and storage. The covers are for operator safety, but
also protect the internal components of the machine from the environment.

2. Avoid storage of the machine outdoors for long periods of time. Cover the machine with a tarp
to protect it, but provide good ventilation to prevent condensation and rust.

3. Keep the machine clean. This will increase the life of the machine and make maintenance
easier. A clean machine will provide a clean product.

4. Before operating the machine, visually inspect for foreign objects, debris, or anything unusual.
If something doesn’t seem correct, inspect and remedy prior to operation.

5. Keep chains properly tensioned. This will add to the life of the chains and sprockets. The chains
should be just snug. An over-tightened chain is just as bad for the machine as a loose chain.
Idler sprockets are provided on each chain for this purpose.

6. Lubricate the chains a minimum of every 40 hours of operation. It is preferable to use a dry
motorcycle chain lube or equivalent.

7. Lubricate the 2-main drive gears a minimum of every 30 hours of operation. Use of an Open
Gear Spray Lubricant is recommended. (Figure 19 & Figure 20 on page 32).

8. Keep Entry Guide Carriage (Figure 3 on page 7) clean and lubricate as needed with Spray Lube.

9. Lubricate 7 Acme Shafts (Figure 4 on page 8) with Spray Lube as needed.

10. Lubricate Mitre-Gears (Figure 4 on page 8) on ends of Acme Shafts with Spray Lube as needed.

11. Keep Arbor Cradles (Figure 12 on page 22) lubricated with Clear Grease.

12. Lubricate Arbor Nut (Figure 11 on page20) using a grease gun with EP Grease when threads
begin to look dry.

13. Clean Forming Rollers as needed with a Scotch Brite Pad and a small amount of solvent.

14. Clean Drive Rollers with soap and water, or mild solvent free spray cleaner. CAUTION: Do
not use harsh chemicals or solvents or damage will occur.

15. Lubricate both faces of the Shear Blades and Dies (Figure 21 on page 35) a minimum of once
daily with Spray Lube. More should be added as needed to prevent the cut edges from
deteriorating.

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 CHAPTER 4
GENERAL MAINTENANCE
Recommended Lubricants and Fluids

The following lubricants are available from New Tech Machinery.

Spray Lube for:

Shear Blades, Shear Dies, Entry Guide, Acme Shafts and Mitre Gears
Super Lube - Multi-Purpose Synthetic Aerosol Lubricant with Syncolon (PTFE)
NTM PN: LUBE-SPRAY - 11oz can

Clear Grease for:

Arbor Cradles
Synthetic Extreme Pressure, High Temperature Grease with Syncolon (PTFE)
NTM PN: LUBE-GEL - 400-gram container

EP Grease for:
Arbor Nuts and Pillow Blocks
Grease - Lubricants Type: Moly Ep Grease
NTM PN: LUBE-GREASE - 14 Ounce Container

Open Gear Spray Lubricant for:

Main Drive Gears
Open Gear and Wire Rope Lubricant
NTM PN: LUBE-GEAR - 11 oz. Aerosol Can

Hydraulic Fluid (32AW) for:

Hydraulic Tank
NTM PN: HYD-200-018 - 5 Gallons
(5 Required)

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 CHAPTER 4
GENERAL MAINTENANCE

Figure 3: Entry Guide

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 CHAPTER 4
GENERAL MAINTENANCE

Figure 4: Acme Shafts and Width Adjustment

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 CHAPTER 5
ELECTRICAL CONTROLS AND OPERATION

ELECTRICAL CONTROLS AND OPERATION

For Models with an Electric Motor or Both Gas and Electric Motors

POWER CORD REQUIREMENTS

It is very important to follow the power cord requirements prescribed by the motor and
electrical control manufacturers to maintain their respective warranties. Make sure the cord
being used is marked properly. Do not assume that because an extension cord looks heavy
enough that it is the right gauge. Use of the wrong gauge extension cord will void the
warranty on motor and electrical controls.

GENERATOR USE FOR ELECTRIC MOTOR MACHINES

If a generator will be used to power the machine it must be large enough to handle the amp
draw requirements of the motor. Contact the local generator supplier for proper sizing and
refer to the specification plate on the electric motor. Use of an improperly sized generator
will cause a low voltage situation of the electric motor and controls which will void the
warranty.

MANUAL CONTROL PANEL OPERATION:

(See Figure 6)
A. JOG FORWARD-REVERSE Switch
This selector switch is used to load coil into the machine. Jog the material through
the machine in small increments until it clears the shear dies. There is a Jog
Forward-Reverse Switch at both the exit and entry ends of the machine.
B. SHEAR DOWN (Green button)
Pressing this button once will cycle the shear to the bottom of its stroke and return it
back to the top or home position. This is one shear cycle.
C. SHEAR UP (Red button)
Pressing this button during the down cycle of the shear will immediately send it back
to the top or home position.
D. STOP FEED (Red button)
This button acts as an emergency stop for the drive system when using the Length
Control Computer.
E. ENGINE START (Green button)
The Emergency Stop buttons must be pulled out before the Engine Start Button
will function. Press and hold this button until the engine starts.
F. EMERGENCY STOP (Raised Red Mushroom button)
Once the machine is running, pushing this button in will stop all functions and
completely shut down the machine including the engine. If the shear is in the down
cycle it will freeze it in position. The shear will default back to the top or home
position once the engine or motor is re-started. There are Emergency Stop buttons at
both the exit and entry ends of the machine, and they both must be pulled out in
order for the machine to operate. If either Emergency Stop button is pressed in, the
button at the exit end will light up as an indication.

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 CHAPTER 5
ELECTRICAL CONTROLS AND OPERATION
VFD ENCLOSURE OPERATION:
(See Error! Reference source not found. )
A. ON-OFF Switch
Turn this switch to ON to power up the machine and OFF to shut the machine down when it
is not in use.
B. ELECTRIC-GAS Switch
For machines equipped with both an electric motor and a gas engine, use this switch to
select which power supply will be used.

CIRCUIT BREAKERS AND FUSES

If the machine is not powering on correctly it is possible that a circuit breaker is tripped or a
fuse is blown. Check if the breakers have been tripped inside the VFD Enclosure as shown in
Error! Reference source not found.. There is also a fuse inside the Manual Control Panel as
shown in Figure 5. Check the fuse with a continuity tester. If it is bad, replace with a new fuse
of the same amp rating.

Figure 5: Main Control Box Fuse

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 CHAPTER 5
ELECTRICAL CONTROLS AND OPERATION

Figure 6: Controls Gas/Electric

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 CHAPTER 5
ELECTRICAL CONTROLS AND OPERATION

Figure 7: VFD Enclosure

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 CHAPTER 5
ELECTRICAL CONTROLS AND OPERATION
MANUAL CONTROL PANEL OPERATION:

For Models with a Gas Engine Only

(See Figure 8 )
G. FORWARD-REVERSE Switch
This selector switch controls the direction of movement of the material through the
machine. Select forward to feed material and run panel through the machine.
NOTE: For operator safety, the machine will not run continuously in reverse.
H. JOG-RUN Switch
This selector switch allows the machine to run continuously, or jog material through
the machine. Select JOG to load coil into machine and to move material through the
machine in small increments until it clears the shear dies. Select RUN after material
has cleared the shear, and the machine will be ready to run panel.
NOTE: The LENGTH CONTROL LIMIT SWITCH must be plugged in to the
Limit Switch Plug at the bottom of the Manual Control Box Assembly to run
continuously.
I. START FEED (Green button at Entry and Exit End)
This button is used to activate the drive system of the machine. (Jog only unless limit
switch is plugged in)
J. STOP FEED (Red button at Entry and Exit End)
This button acts as an emergency stop for the drive system when using the Length
Control Limit Switch. Pressing either the entry or exit button will stop the drive
system of the machine in case of an emergency.
K. SHEAR DOWN (Green button)
Pressing this button once will cycle the shear to the bottom of its stroke and return it
back to the top or home position. This is one shear cycle
L. SHEAR UP (Red button)
Pressing this button during the down cycle of the shear will immediately send it back
to the top or home position.
M. EMERGENCY STOP-POWER ON (Raised Red Mushroom button)
Function #1 (Power On)
Pull this button OUT prior to starting the machine.
Function #2 (Emergency Stop-Power Off)
Once the machine is running, pushing this button in will stop all functions and
completely shut down the machine including the engine. If the shear is in the down
cycle it will freeze it in position. The shear will default back to the top or home
position once the engine or motor is re-started. This button is also used to shut the
machine down when not in use. Failure to push this button in prior to storage, even
overnight, could result in a dead battery on gas engine models.
N. MOTOR START (Green button)
The Emergency Stop button must be pulled out before the Start Button will
function.
Press this button momentarily to start the Electric Motor machine.
Press and hold this button until the engine starts on a Gas Engine model.

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 CHAPTER 5
ELECTRICAL CONTROLS AND OPERATION
MAIN CONTROL CABLE
(See Figure 9)
A. The main control cable is the communication cable for the Manual Control Panel
described above, and the Computer Batch and Length Control Computer covered in
Appendix B. This cable must be connected to one or the other in order for the
machine to operate.
B. The Main Control Cable exits thru the panel below and under the left corner of the
Manual Control Panel. There are three cables there and it is the larger diameter plug
of the three. It has a key and slot configuration that must be aligned before the
male/female connection can be made on the Manual Control Panel or Batch and
Length Control Computer. This prevents misalignment and damage to the pins.

Manual Control Panel Connection

Connect the Female end of the Main Control Cable to the panel mounted male
connection located at the bottom left corner of the Manual Control Panel. Make sure
that the key and slot are aligned and carefully start the threads on the connection and
turn clockwise until snug.

Batch and Length Control Computer Connection

Connect the Female end of the Main Control Cable to the panel mounted male
connection located in the bottom of the computer on the right side. Make sure that
the key and slot are aligned and carefully start the threads on the connection and turn
clockwise until snug.

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 CHAPTER 5
ELECTRICAL CONTROLS AND OPERATION

REMOTE LIMIT SWITCH

(See Figure 10 )
NOTE: The machine will not run continuously in the forward direction unless the Remote
Limit Switch is plugged into the machine. The Remote Limit Switch is used for panel length
control. It is designed to attach to the right side of the optional Run Out Tables (see page14)
available for the machine. Plug the female end of a 3-wire 14-gage extension cord into the limit
switch, and the male end into the female Limit Switch Plug located at the bottom of the Control
Panel Assembly. The length of the panel to be ran determines the length of the extension cord
needed. Run out a panel to the desired length and stop the machine. Slide the Remote Limit
Switch onto the bottom of the angle on the right side of the run out table so that the ARM of the
switch is against the end of the panel. Pull the limit switch back toward the shear until a click is
heard in the Limit Switch Head and secure the limit switch at this location. Cut and remove the
set-up panel from the table. Push the start button and run the next panel allowing the limit
switch to stop the machine. Measure this second panel before cutting to determine if it stopped
in the correct position and make the necessary adjustment to the limit switch to obtain the
desired length. Repeat as necessary.

FUSES
( Figure 5)
All machines, gas or electric powered, have a fuse inside the Manual Control Panel. Check the
fuse with a continuity tester. If it is bad, replace with a new fuse of the same rating.

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 CHAPTER 5
ELECTRICAL CONTROLS AND OPERATION
GAS ENGINE ONLY MACHINES

Figure 8: Controls Gas Only

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 CHAPTER 5
ELECTRICAL CONTROLS AND OPERATION

Figure 9: Main Control Cable

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 CHAPTER 5
ELECTRICAL CONTROLS AND OPERATION

Figure 10: Run Out Table and Remote Limit Switch

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 CHAPTER 6
REEL STANDS, REELS, AND EXPANDABLE ARBORS

REEL STANDS, REELS AND EXPANDABLE ARBORS

EXPANDABLE ARBOR
(Figure 11)
The Expandable Arbor adjusts to accommodate coils with 16” to 20” inside diameters by expanding
into the ID of the coil.

THREADED NUT
The threaded nut should always be on the right side of the machine, and the tail of the coil should
always be routed over the top and pointing toward the exit or shear end of the machine.
This threaded nut is used to increase or decrease the outside diameter of the arbor. Turning the nut
clockwise will increase the outside diameter of the arbor, and counter-clockwise rotation will
decrease the arbor size. There is a grease zerk in the collar of the threaded nut that should be
lubricated at least twice a year, or whenever grease in not visible on the threads of the shaft.

END COLLAR
The End Collar has two positions.
Position “A” is used for coils with inside diameters of 16”.
Position “B” is used for coils with inside diameters of 20”.

To adjust from one position to the other, remove 2 screws “C” until end collar is free to slide. Slide
it to the inside position for 20” ID or outside position for 16” ID coil. Align it to the respective
threaded holes in the reel shaft. Re-insert and tighten "C" bolts to lock the end collar to the shaft.

LOADING EXPANDABLE ARBORS WITH COIL

1. Using the Threaded Nut, collapse the arbor small enough to fit into the inside diameter of
the coil.
2. Slide the Expandable Arbor into the center of the coil making sure the threaded nut is on the
right and the tail of the coil is over the top and pointed toward the exit end of the machine.
3. Turn the Threaded Nut clockwise until the Support Bars on the arbor are just snug against
the inside of the coil.
4. Slide the arbor left or right to get the correct dimension measuring from the edge of the coil
to the end of the Support Bar on the Threaded Nut side. (Figure 11)
5. Finish by rotating the Threaded Nut clockwise until the Support Bars are very tight against
the inside of the coil. Verify that the coil location is correct, and re-adjust if necessary. The
Coil and Arbor are now ready for loading. (see LOADING REELED COIL on page 23)

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 CHAPTER 6
REEL STANDS, REELS, AND EXPANDABLE ARBORS

Figure 11: Expandable Arbor Set-Up

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 CHAPTER 6
REEL STANDS, REELS, AND EXPANDABLE ARBORS

LOADING INSTRUCTIONS FOR THE TRIPLE OVERHEAD REEL RACK

If you have the triple overhead reel rack care must be taken in loading the coils so that the tongue
weight of the trailer is in a safe range. Please observe the following guidelines:

1. If you have one coil, load it in the center position.

2. If you have two full coils, load them in the front two positions and take material from the
front coil first, then the center coil.
3. If you have three full coils, take material from the rear coil first (the one closest to the
shear), then the front coil, then the center coil.
4. If you have coils of varying weights, put the heaviest one in the center position, the second
heaviest in the front position, and the lightest one in the rear position.

REMOTE DECOILER

If a Remote Decoiler is used it should be placed 8 to 10 feet behind the machine. Align it as close
as possible to the Right-Side Entry Guide line of fire, making the side of the coil and reel parallel to
the machine. NOTE: The closer the Decoiler and reel are set to the machine, the more critical this
alignment becomes.

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 CHAPTER 6
REEL STANDS, REELS, AND EXPANDABLE ARBORS

Figure 12: Expandable Reel Assembly

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 CHAPTER 6
REEL STANDS, REELS, AND EXPANDABLE ARBORS

LOADING REELED COIL

Caution:
Always use a forklift or other approved lifting device to load or unload Fixed Reels or
Expandable Arbors loaded with coil.
The Lifting Holes in the Fixed Reel sides are provided to make loading safer and easier.
DO NOT use lifting straps through the lifting holes as the sharp edges may cut the straps.

1. Prepare the reel stand by making sure the Hold Down Bars are in the unlocked and open
Position (Figure 12).
2. Using an approved lifting device, lift the reeled coil into the cradles on the reel stand making
sure that the tail of the coil is in the correct position (Figure 14) then remove the lifting device.
3. Rotate the Hold Down Bars (Figure 12) to the closed position and thread the handle onto the
hold down bolt. If material is going to be used from this coil, tighten the left and right handle
just snug. Final adjustment of tension should be made while running a panel to keep reel from
unwinding material too fast. As the coil becomes smaller, re-adjustment will need to be made.
Caution: Do Not over tighten Hold Down Bars. Drive and/or electrical system failure
may occur.
4. If the machine will be transported after loading coil, tighten the Hold Down Bars securely to
keep coil from unwinding during transport, and secure the loose end of the material to the coil.
5. Before transporting the loaded Expandable Arbor, the coil should be secured around the
outside edges through the inside diameter using a strap, rope, etc. to prevent the coil from
telescoping (Figure 11).

NOTE: Make sure Hold Down Bars are tightened securely and coil is properly tied off
before transporting machine.

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 CHAPTER 6
REEL STANDS, REELS, AND EXPANDABLE ARBORS
FEEDING COIL INTO THE MACHINE

Before feeding coil into the machine it is necessary to trim the corners of the leading edge to ensure
smooth loading. Cut a triangle from the left corner that is about 1” wide. On the right corner, cut it
out in the shape shown below. A template has been provided with the machine to make this easier,
but if it has been lost you can follow the dimensions in the figure.

Figure 13: Trim Material

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 CHAPTER 6
REEL STANDS, REELS, AND EXPANDABLE ARBORS

Figure 14: Material Routing

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 CHAPTER 7
HYDRAULIC SYSTEMS

HYDRAULIC SYSTEMS

Maintenance
(Figure 15)
The hydraulic system in the machine is very durable and reliable. It must be properly maintained to
ensure trouble free operation and longevity. The factory has installed a 32 weight AW hydraulic
fluid. Because this equipment is used primarily outdoors and exposed to the elements, it is
recommended that the oil be changed annually. Hydraulic oil will degrade if it remains stagnate in
the system for long periods of time. Check the fluid level weekly. It should be approximately 6-1/2”
below the top of the filler neck. When checking the fluid level, also note the color and condition of
the fluid. It should be clear in color.

Hydraulic Fluid Troubleshooting

CONDITION SOLUTION

1 White milky color indicates water contamination. Change the fluid.

2 Dark fluid usually indicates a dirty oil filter. Replace the oil filter.

3 Foamy fluid will cause a noisy pump and slow erratic Check fluid level and bleed off air
operation of the system. The cause is usually low oil by pushing the shear down button
level or air in the system. and holding for 10 seconds.

4 Machine runs slow after continuous operation. Check Allow to cool down. Move to a
hydraulic fluid temperature, it should be no more than shaded area if possible.
140°F (60°C).

Changing Hydraulic Fluid and Filter

(Figure 16 & Figure 17)
The hydraulic fluid should be changed at least once a year. More frequently if the machine is
constantly in operation in a dusty environment or, if the fluid becomes contaminated. To change the
fluid:
1. Remove Left Side Cover #3 and set aside.
2. Locate the Drain Plug located on the bottom of the Hydraulic Tank as shown in Figure 15.
3. Remove Filler Cap.
4. Place a container under the drain plug to catch the old fluid.
5. Remove the Drain Plug and drain the fluid into the container. Discard of Properly.
6. Loosen, remove and discard the used Hydraulic Filter.
7. Re-install the plug and new hydraulic filter and fill the tank with fresh 32 weight fluid until
it is 6-1/2” below the top of the Filler Neck “F” (approximately 24 gal).

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 CHAPTER 7
HYDRAULIC SYSTEMS

Figure 15: Hydraulic System – Overview

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 CHAPTER 7
HYDRAULIC SYSTEMS

Figure 16: Hydraulic System – Details

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 CHAPTER 7
HYDRAULIC SYSTEMS

Figure 17: Hydraulic Fluid Level

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 CHAPTER 8
DRIVE SYSTEM

DRIVE SYSTEM
(Figure 18, Figure 19 & Figure 20)
The drive system of the machine consists of twelve top and twelve bottom polyurethane drive
rollers. They are connected together via chain and sprocket and there are chain tensioners on each
assembly. The drive system is powered by a hydraulic motor which transfers power to the drive
assemblies using spur gears and a top and bottom drive shaft.

1. Clearance between the top and bottom drive rollers is factory set at ¾ of a turn of
pressure past the point of contact. This will drive material up to 22ga. through the
machine without the need for adjustment. If adjustment becomes necessary due to
slippage, pressure can be added. Do not add more than ¼ turn beyond the factory
setting.
To add pressure: Loosen two Lock-Down Bolts “B” 1/8 of a turn. Loosen lock nuts on
the two corresponding Jack Bolts “A”. Tighten Bolts “A” 1/8 of a turn. Re-tighten the 2
lock nuts on Jack Bolts “A” to lock in adjustment. Repeat this procedure for the other 11
drive assemblies. Test for result and repeat one more time if necessary.
To remove pressure: Loosen the two lock nuts on Jack Bolts “A”. Loosen the two Jack
Bolts “A” 1/8 of a turn. Tighten the two corresponding Lock-Down Bolts “B” 1/8 of a
turn. Tighten the two lock nuts on Jack Bolts “A” to lock in adjustment. Repeat this
procedure for the other 11 drive assemblies.
2. To adjust chain tension, loosen the bolts on the idle sprockets, move the sprocket as
needed, and tighten the bolt. The chains should be snug, but not too tight.
3. The chains used in this system are #50 Roller Chain. See Figure 20 for chain locations
and lengths if chain replacement is necessary.
4. The polyurethane drive rollers will eventually need cleaning. This will become evident
when they start leaving a stripe the width of the drive roller on the formed panels that
doesn’t come off easily or if a material is used with an oily film on it. Avoid cleaning the
drive rollers with harsh chemicals or solvent. These products will attack the
polyurethane and cause irreversible damage. Use of these products will void the
warranty on the drive rollers.
Clean the rollers with mild soap, water and a rag. Caution must be taken around the
moving parts of the machine during the cleaning process.
5. Covers should be kept on the machine during operation and storage. Ultraviolet light
will attack the polyurethane drive rollers and cause deterioration. Again, this type of
damage is not covered under the warranty.

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 CHAPTER 8
DRIVE SYSTEM

Figure 18: Drive Roll Assembly View

31
 CHAPTER 8
DRIVE SYSTEM

Figure 19: Gears and Shafts

32
 CHAPTER 8
DRIVE SYSTEM

Figure 20: Chains Upper and Lower

33
 CHAPTER 9
SHEAR ASSEMBLY

SHEAR ASSEMBLY
OPERATION
Push the SHEAR DOWN button to activate the shear cycle and cut material. IN CASE OF
AN EMERGENCY: Push the SHEAR UP button during the down cycle to immediately
send the shear up to the home position.
The shear is electrically activated and hydraulically driven.
The two Top Limit Switches and single Bottom Limit Switch control the cycle of the shear.
The Top Limit Switches electronically lock out the drive system when the shear is in motion.
The Bottom Limit Switch sends the shear back up once the end of the stroke is reached.

SHEAR ADJUSTMENTS (Figure 21)

The shear is adjusted at the factory and should not need to be adjusted. However, if the panel
is rubbing on the shear dies or hanging up on them follow the procedure below to correct the
problem. WARNING: When working near the shear it is essential that you turn off the
machine and remove the power. The blades are powerful and can cut through your hand or
finger.

Bottom Shear Dies (Detail A)

1. The bottom dies should be adjusted 1/32” below the bottom corners of the panel. Loosen
the (2) “A” bolts on the left and right Front Vertical Plates. Loosen the (2) lock nuts on the
(2) Height Adjustment bolts “B”. (See Figure 21)
2. Tightening bolts “B” will lower the shear, and loosening them will raise it. Adjust each side
as needed to properly set the bottom dies to the correct spacing from the bottom corners of
the panel.
3. After adjustments have been made, tighten (2) “A” bolts and (2) Lock Nuts on Height
Adjustment Bolts “B”.

Right Side Dies and Rib Dies

If the panel is rubbing on any of these dies you may need to adjust them either left or right so they
no longer touch the panel. With the panel extending a few inches past the shear look through the
dies at the gap between the panel and the dies. The gap should be about the same on the left and
right sides of the dies. If they need to be adjusted follow the steps below.
1. Loosen the “C” bolts for whichever dies need to be moved. You may need to back the panel
up to access the bolts on the back side of the shear.
2. Move the dies left or right as needed to get the gap even on either side.
3. Re-tighten the “C” bolts.

Left Side Dies

The left side dies should be located so that the etched line is roughly aligned with the tip of the
folded over hem (see Detail B). They should not need to be moved because there is nothing on
these dies for the panel to rub against or crash into, but if they do follow the steps below.
1. Loosen the “C” bolts on the left dies and the “D” bolts on the shear blades.
2. The dies and blades need to both be moved the same amount. Adjust them both and make
sure the blade is against the pin in the die.
3. Re-tighten the “C” and “D” bolts.

34
 CHAPTER 9
SHEAR ASSEMBLY

Figure 21: Entry/Exit Views

35
 CHAPTER 10
WIDTH ADJUSTMENT

WIDTH ADJUSTMENT
Width adjustment crank handle

The crank handle on the right side of the machine is used to make fine adjustments to the
finished width of the panel. It is set at the factory to produce a panel with 16” of coverage
and should not need to be adjusted. However, if it does need to be adjusted follow the
procedure below.

1. Remove the panel material from the machine. Do not attempt to turn the
handle with material in the machine.
2. Disconnect the power and remove the top cover closest to the shear. (See
Figure 22,Page 37).
3. Measure the distance between the Left and Right Gold Tooling Angles and
make note of it. (See Figure 22, Page 37).
4. Figure out how far apart the angles need to be by adding or subtracting as
needed from the distance you measured. For example, if the rails are 22-1/4”
apart and your panel is 1/16” too narrow, then you need to move the angles
to 22-5/16” apart.
5. Push the crank handle in to engage it, see Figure 25, then turn it clockwise
to move the angles further apart or counterclockwise to move them closer
together. You shouldn’t have to turn it very far. For reference, a full turn of
the handle will move the rails about 1/8”.
6. Cut off a piece of material about 6’ long and run it through the machine,
stopping just before the shear. Jog it slowly through the shear while looking
at the dies. If the panel crashes into the dies or rubs against them then back
up the panel and move the dies as needed. See the section on adjusting the
shear dies for more information.
7. Run the panel about 1 foot past the shear, cycle the shear, and discard the
piece. Then cut two pieces that are about 1 foot long and use them to test the
finished width. If further adjustment is needed then repeat the steps above. If
the panel is good then replace the top cover and continue producing panels.

36
 CHAPTER 10
WIDTH ADJUSTMENT

Figure 22: Width Adjustment

37
 CHAPTER 10
WIDTH ADJUSTMENT

LEFT TOOLING RAIL TO ENTRY GUIDE ALIGNMENT

Figure 23: Tooling Rail Adjustment Handle

Figure 25: Engaged

Figure 24: Disengaged

38
 CHAPTER 11
ENTRY DRUM ASSEMBLY

ENTRY DRUM ASSEMBLY

The Entry Drum Assembly supports the panel as it goes through the entry guide. The
Entry Drums should be positioned so that the left and right drums are lined up with the
edges of the panel and the center drum is in the center of the panel.
To adjust the entry drums:
1. Using a 3/16” Allen wrench, loosen the Shaft Collars “E”, on either side of the
Entry Drums that need to be adjusted (Figure 26).
2. Slide the Entry Drums to the correct position.
3. Slide the Shaft Collars “E” against the sides of the drums and lock them into
place.

Figure 26: Entry Drum

39
 CHAPTER 11
ENTRY DRUM ASSEMBLY

ENTRY DRUM POSITIONS

The Entry Drum can be mounted in two different positions on the entry end of the frame.
There is an upper position for use with the Overhead Reel Rack, or a lower position for
use of any floor mounted Decoiler. (See Figure 27).

Figure 27: Entry Drum Upper/Lower Position

40
 CHAPTER 12
PROFILE ADJUSTMENTS

PROFILE ADJUSTMENTS
Care must be taken when making any adjustments to the roller systems. A slight change
can have dramatic effects.

ECCENTRIC SHAFTS
This machine is equipped with eccentric shafts on selected sub stations for adjusting the
angles and gaps in the panel.

Figure 28: Eccentric Shafts

To adjust an eccentric shaft, use the following procedure:

1. Mark the current orientation of the shaft to serve as a starting point of reference
and a point to return to if the adjustment yields negative results.
2. Loosen the set screw and/or bolt that holds the shaft in place.
3. Rotate the shaft to the desired angle (See Figure 30 - Figure 32).
4. Re-tighten the set screw and/or bolt.

41
 CHAPTER 12
PROFILE ADJUSTMENTS

Figure 29: Adjusting Eccentric Shafts

Figure 30: Eccentric Shaft Proper Adjustment

42
 CHAPTER 12
PROFILE ADJUSTMENTS

Figure 31: Eccentric Shaft Too Loose

Figure 32: Eccentric Shaft Too Tight

43
 CHAPTER 12
PROFILE ADJUSTMENTS
To fine tune the bends in panel refer to Figure 33 through Figure 36 to determine which
station will change the bend needing adjustment.

Figure 33: Adjusting Station R-6

Figure 34: Adjusting Station R-10

44
 CHAPTER 12
PROFILE ADJUSTMENTS

Figure 35: Adjusting Station R-15

Figure 36: Adjusting Station L-14

CAMBER STATIONS
This machine is equipped with two camber stations toward the exit end of the machine
(L-13 and R-14) that can be used to make the panel run straight if it is going uphill or
downhill. (See Figure 37).

45
 CHAPTER 12
PROFILE ADJUSTMENTS

Figure 37: Camber Adjustment - Uphill/Downhill

If the panel is going uphill (away from the house) or downhill (into the house), ensure
that the run-out stands are properly adjusted for height and that the panel is able to run
straight out of the machine. If the run-out stands are in the correct alignment, adjust the
camber stations as necessary using the following procedure:

1. Create a base point to start from by marking the top camber bolt as well as
scribing a line across the center block and the two uprights.
2. If the panel is running downhill, adjust either L-13 or R-15 by turning the top bolt
counterclockwise. If the panel is running uphill, adjust either L-13 or R-15 by
turning the top bolt clockwise.

Note: It is recommended to make small adjustments such as a 1/8 turn. Then run a panel
to see the results after each adjustment. Over adjusting the stations can have
unpredictable results.

46
 CHAPTER 12
PROFILE ADJUSTMENTS

Figure 38: Camber Adjustment

47
 CHAPTER 13
USING UNDERSIZED COIL

USING UNDERSIZED COIL

Undersized coil can be used in the Wave machine by moving the left Entry Guide Shoe
to the right and adding shims behind station L-1. This will make the nail flange narrower
but keep the coverage the same. Follow the procedure below:
1. Loosen the Lock Down Handle on the left entry guide (Figure 39).
2. Cut a 12” long piece of gage material from the coil that will be used in the
machine.
3. Slide gage material between the left and right entry guides.
4. Slide the Left Entry Guide to the left or right to accept the new coil width. Make
sure that the material is captured snugly between the entry guides and re-tighten
the Lock Down Handle.

Figure 39: Entry Guide Shoe and Lock Down Handle

5. Measure the width of the coil and subtract it from 24”. That will be the amount
you need to shim Station L-1 away from Tooling Rail.

48
 CHAPTER 13
USING UNDERSIZED COIL
6. Unbolt Station L-1 and add the shims calculated above. Bolt the station back to
the rail. (Longer bolts may be needed) Figure 40.

Figure 40: Shim Placement

49
 CHAPTER 14
ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS

ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS

Figure 41: Wav Center Roller System

50
 CHAPTER 14
ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS

Figure 42: Wav Left and Right Roller System

51
 CHAPTER 14
ROLLER SYSTEMS AND PANEL PROFILE DRAWINGS

Figure 43: Wav Panel Profile

52
 CHAPTER 15
RUN OUT TABLES AND REMOTE LIMIT SWITCH

RUN OUT TABLES AND REMOTE LIMIT SWITCH

Figure 44: Run Out Tables

53
 CHAPTER 16
TROUBLE SHOOTING

TROUBLESHOOTING
The hydraulic system operates the Shear and Drive assemblies. They are interfaced
together and electronically activated. The hydraulic system pressure is factory set at 2000
psi and should not be changed. Some of the common problems that occur and their
solutions follow below.

1. Shear travels to the bottom of the stroke, stops, and the hydraulic system
continues laboring. Pushing the Red Shear Up Button returns it to the top of
stroke.

SOLUTION: Loosen Screws “A” (Figure 45). Press Shear Down. While the hydraulic
system is laboring and the shear is stuck in the lower position, raise the Bottom of Stroke
Limit switch until it clicks and the Shear Goes up. Tighten Screws “A”. Note: If the
limit switch is adjusted too far up, problem #2, below, will be seen on the next cut made.

Figure 45: Bottom of Stroke Limit Switch

54
 CHAPTER 16
TROUBLE SHOOTING
2. Shear travels to the bottom of the stroke and returns to the top of the stroke
without cutting the panel completely through.

SOLUTION: Loosen Screws “A” (Figure 45). Lower the Bottom of Stroke Limit
switch. Tighten Screws “A”. Press the Shear Down button and repeat
adjustment if necessary. Note: If the limit switch is adjusted too far down,
problem #1, above, will be seen on the next cut made.

3. Shear is at the top of the stroke; the hydraulic system continues laboring and
the next panel cannot be run.

SOLUTION: Remove the Shear Cover. Lift the arms on the limit switches
(Figure 46) one at a time. If one of them stops the hydraulic system
laboring then that Limit Switch arm needs to be adjusted. If neither of
them stops it, lift both arms at the same time to see if it stops. If it does
then both arms need adjusting.
ADJUSTMENT: Shut off the machine and disconnect the power. Loosen the Top
Limit Switch Adjustment Screws (Figure 46) just enough so that the
Mount Plate can be moved, and slide the Mount Plate all the way up.
Slowly lower it back down until the switch clicks. Re-tighten the screws.
Adjust one or both sides as required from the test above. Start the
machine. If the adjustment(s) were done correctly, the hydraulic system
should no longer be laboring and the next panel can be produced.

55
 CHAPTER 16
TROUBLE SHOOTING

Figure 46: Limit Switch Adjustment

4. Manual Control Panel buttons do not work.

SOLUTION #1: Check fuse inside of Manual Control Box. See the Electrical
Controls and Operation Section for details.

SOLUTION #2: If the machine is equipped with a gasoline engine, check the
condition of the battery. The control system requires 12 volts to operate
properly. Replace or charge battery as required.

56
APPENDIX A

ELECTRICAL SCHEMATICS
Sheet
Drawing Number Number Description
WAV-380-000 1 Electrical Assembly – Parts List
WAV-380-000 2 Electrical Assembly – Detailed View
WAV-380-000 3 Electrical Assembly – Detailed View
WAV-380-000 4 Electrical Assembly – Cables

WAV-381-000 1 Manual Control Panel – Assembly

WAV-381-000 2 Manual Control Panel – Wiring Schematic

WAV-384-000 1 VFD Enclosure Assembly – Parts List

WAV-384-000 2 VFD Enclosure Assembly – Wiring Schematic

1
 PARTS LIST PARTS LIST
ITEM QTY PART NUMBER TITLE ITEM QTY PART NUMBER TITLE
1 1 5VC-240-280 B.O.S. LIMIT SWITCH MOUNT PLATE 20 1 FAS-SCH-430 1/4-20 X 5/16 DIA X 1-1/4 SHLDR BLT
2 2 ELC-100-011 CABLE, 4-PIN MALE-FEMALE x 2M (NOT SHOWN) 21 6 FAS-SPN-332 SCREW, PAN HEAD, #8-32 x 1¼", PHILLIPS
3 1 ELC-100-012 PROXIMITY SENSOR, 50MM 22 2 FAS-SRM-207 SCREW, PAN HEAD, 8 x 1/2", PHIL, SELF-TAPPING
4 1 ELC-100-015 CABLE, 5-PIN MALE x 6M 23 3 FAS-WSF-260 WASHER, FLAT, 1/4" SAE
5 14 ELC-110-023 FERRULE, 20GA, WHITE (NOT SHOWN) 24 2 FAS-WSF-262 WASHER, FLAT, 5/16" SAE
6 1 ELC-180-301 ENCODER, 6" CIRC, 600CT 25 6 FAS-WSF-333 WASHER, FLAT, #8 SAE ZI
7 1 ELC-180-308 CABLE, HYDRAULIC VALVES (NOT SHOWN) 26 6 FAS-WSF-344 WASHER, FLAT, #10 SAE
8 2 ELC-400-105 CABLE, 4-PIN, MALE X 2M 27 2 FAS-WSL-256 WASHER, LOCK, 5/16"
9 1 ELC-400-106 CABLE, 3-PIN, MALE X 2M 28 6 FAS-WSL-320 WASHER, LOCK, SPLIT, #8
10 3 ELC-400-126 LIMIT SWITCH 29 8 FAS-WSL-404 WASHER, LOCK, SPLIT, #10
11 -3 ELC-425-018 LOCKNUT, 1/2" NPT (NOT SHOWN) 30 1 HYD-200-134 DIN CONNECTOR, 4-PIN
12 -3 ELC-425-019 GASKET, YELLOW NEOPRENE (NOT SHOWN) 31 1 MHW-450-073 GUIDE WHEEL, 2" X 7/8"
13 3 ELC-450-006 STRAIN RELIEF, 1/2" NPT .10-.30" 32 1 PLC-140-000 PROXIMITY SENSOR WELDMENT, WAV
14 1 FAS-HC5-118 HEX HEAD CAP SCREW, 1/4-20 x 1" LG. 33 1 PLC-370-001 ENCODER MOUNT, WAV
15 2 FAS-HC5-130 HEX HEAD CAP SCREW, 5/16-18 x 1" LG. 34 1 PLC-370-002 BOTTOM ROLLER MOUNT
16 2 FAS-HC5-278 HEX HEAD CAP SCREW, 1/4-20 x 2" LG. 35 1 SSP-340-276 LIMIT SWITCH MOUNTING PLATE
17 3 FAS-NUY-188 NYLOC HEX NUT, #1/4-20 36 1 SSP-340-279 LIMIT SWITCH MOUNT PLATE TOP LEFT
18 8 FAS-SCC-317 SOCKET HEAD CAP SCREW, 10-32 x 5/8" 37 1 WAV-381-000 CONTROL BOX ASSEMBLY
19 2 FAS-SCC-386 SOCKET HEAD CAP SCREW, 10-24 x 3/4" 38 1 WAV-382-000 REMOTE PUSH BUTTON BOX, WAV

REMOTE PUSH
BUTTON STATION

SHEAR LIMIT
SWITCHES

PUSH BUTTON BOX

ENCODER
PROXIMITY SENSOR

MATERIAL
NEW TECH MACHINERY
WEIGHT FINISH
SEE BOM 11.115 lbs NONE CORP.
REV ECR NO. DATE RELEASED BY TOLERANCES DRAWN BY PART NAME

0 NONE 05/08/2017 AJB .XX = `.01 BT

WAV ELECTRICAL ASSY
REVISION
HISTORY

DATE
.XXX = `.005 05/05/2017
FRACTION = `1/32"
CHECK BY PART NUMBER SHEET REVISION
AJB
ANGLE = `1/2°
DATE
05/08/2017
WAV-380-000 1 OF 4 0
 38 22

ENTRY GUIDE
(REFERENCE)

32

31

20
33

16
3 18 29 17
15 27 37
24 23
14

34
6

19

MATERIAL
NEW TECH MACHINERY
WEIGHT FINISH
SEE BOM 11.115 lbs CORP.
REV ECR NO. DATE RELEASED BY TOLERANCES DRAWN BY PART NAME
.XX = `.01 WAV ELECTRICAL ASSY
REVISION
HISTORY

DATE
.XXX = `.005
FRACTION = `1/32"
CHECK BY PART NUMBER SHEET REVISION

ANGLE = `1/2°
DATE
WAV-380-000 2 OF 4 0
 NOTES:
REMOVE LOCKNUT AND GASKET FROM
10 21 25 13 28 STRAIN RELIEF AND RETURN TO STOCK

36 18 29 26
13
25 21 10 26 29 18 35

29 18 1

10 13 21 25 28

MATERIAL
NEW TECH MACHINERY
WEIGHT FINISH
SEE BOM 11.115 lbs CORP.
REV ECR NO. DATE RELEASED BY TOLERANCES DRAWN BY PART NAME
.XX = `.01 WAV ELECTRICAL ASSY
REVISION
HISTORY

DATE
.XXX = `.005
FRACTION = `1/32"
CHECK BY PART NUMBER SHEET REVISION

ANGLE = `1/2°
DATE
WAV-380-000 3 OF 4 0
 8

64" TOS-LEFT

N.O.
BRN BLK
+12v 30
WHT N.C. BLU
32 31

LEFT
8
DO NOT CUT (78")
TOS-RIGHT
N.O.
BLK BLU
40 41
BRN N.C. WHT
43 42

RIGHT
NOTES:
1. USE FERRULES ON ALL CONNECTIONS 9
EXCEPT HYD-ON DIN CONNECTOR 66" BOS

2. REMOVE LOCKNUT AND GASKET FROM STRAIN BLK

61
N.O.
[-]
BLU

RELIEF AND RETURN TO STOCK BRN N.C.

63
3. CUT THE LEFT AND RIGHT LIMIT SWITCH ARMS TO 3 1/2"

BOTTOM
4

HYDRO ON
30 TBD
N.O.
BLK BLU
+12v 51
N.O.
WHT BRN
52 53

HYD - ON GRAY WIRE - NO CONNECTION

MATERIAL
NEW TECH MACHINERY
WEIGHT FINISH
SEE BOM 11.115 lbs CORP.
REV ECR NO. DATE RELEASED BY TOLERANCES DRAWN BY PART NAME
.XX = `.01 WAV ELECTRICAL ASSY
REVISION
HISTORY

DATE
.XXX = `.005
FRACTION = `1/32"
CHECK BY PART NUMBER SHEET REVISION

ANGLE = `1/2°
DATE
WAV-380-000 4 OF 4 0
 PARTS LIST PARTS LIST
ITEM QTY PART NUMBER TITLE ITEM QTY PART NUMBER TITLE
1 1 DCL-100-086 PUSH BUTTON BOX OVERLAY 17 1 ELC-180-351 DIGITAL INPUT MODULE FC4A-N08B1
2 1 DCL-100-087 DECAL, RECEPTACLE OVERLAY, NTM100 18 2 ELC-300-103 PUSH BUTTON, GREEN
4
3 8 ELC-100-025 RECEPTACLE, 4 PIN MALE x.5M 19 1 ELC-300-104 SELECTOR SWITCH, W/1 N.O.
4 1 ELC-100-060 PUSH BUTTON ENCLOSURE 20 2 ELC-300-107 PUSH BUTTON, RAISED RED
5 1 ELC-100-062 ENCLOSURE COVER, 6-HOLES 21 1 ELC-400-045 HOLE SEAL, 1/2" KO
6 1 ELC-100-073 IDEC MODBUS MODULE 22 1 ELC-400-100 RECEPTACLE, 6 PIN, MALE X 1M
7 6 ELC-110-021 FERRULE, 16GA, BLACK (NOT SHOWN) 23 1 ELC-400-110 RECEPTACLE, 8-PIN, MALE X 0.5M
8 100 ELC-110-023 FERRULE, 20GA, WHITE (NOT SHOWN) 24 1 ELC-425-018 LOCKNUT, 1/2" NPT
18
9 6 ELC-110-024 FERRULE, TWIN 18GA, RED (NOT SHOWN) 25 1 ELC-425-019 GASKET, YELLOW NEOPRENE
10 1 ELC-110-050 POWER SUPPLY, PHX 2320131 26 1 ELC-425-028 SPLIT GLAND CORD GRIP, 1/2" NPT
11 1 ELC-140-000 TERMINAL BLOCK/RELAY ASSEMBLY - WAV 27 2 ELC-450-006 STRAIN RELIEF, 1/2" NPT .10-.30" 19
20
12 1 ELC-180-311 RECEPTACLE, 8-PIN, FKFD 8-0.5 28 8 FAS-NUY-186 NYLOC HEX NUT, #10-32
13 1 ELC-180-312 RECEP, 6-PIN, FKFD 6-0.5 29 4 FAS-SRM-203 PHILLIPS PAN HEAD SCREW, 10-32 x 1/2"
18 14
14 1 ELC-180-334 E-STOP NAMEPLATE, NWAR-27 30 8 FAS-WSF-344 WASHER, FLAT, #10 SAE
15 1 ELC-180-335 E-STOP BUTTON, LED, PUSH/PULL 31 1 NTM100-381-001 IDEC FC5A-D16RS1 - PROGRAMMED
20
16 1 ELC-180-347 SAFETY RELAY, JOKAB RT9
15

12

23
13 1

3
EARTH GROUND
ALSO SEE INSIDE OF DOOR
2
27
22

24 25 26
16
29

28 30

17 NEW TECH MACHINERY

MATERIAL WEIGHT FINISH
31 SEE BOM 19.174 lbs NONE CORP.
REV ECR NO. DATE RELEASED BY TOLERANCES DRAWN BY PART NAME
6 0 NONE 01/30/2017 AJB .XX = `.01 BT
CONTROL BOX ASSEMBLY
REVISION
HISTORY

DATE
.XXX = `.005 01/11/2017
FRACTION = `1/32"
CHECK BY PART NUMBER SHEET REVISION
AJB
ANGLE = `1/2°
DATE
01/30/2017
WAV-381-000 1 OF 2 0
 JOG

BRN
BLU
1 5 9 FWD/REV SHEAR DOWN SHEAR UP
205 204 207 206

+24v
2 6 10

[-]
REV N.O. WHT 10 +12v BRN +24v
FWD N.O. BRN 11
PROX NOT USED WHT
WAV ONLY

N.O. N.O. N.O. N.O.

COMM N.O. RED +24v SENSOR [-] BLU [-]
3 7
N.C. GRY 14 P9 SINK BLK 90
P1 E-STOP
N.C. PNK 15
GND

E-STOP
N.C. BLU [-] VFD CONTACTOR +24V BRN 103 4 8 HMT +24v

N.C. GRN 16 VFD STO OUT1 WHT 102

E-STOP
NOT USED YEL STO IN1 BLU 101 STOP ENGINE START
P10 HMI HMI 211 +12v 219 214 220
TEMP BLK MODBUS QCPP POWER COMM
NOT USED BRN
VALVES KILL (GAS)
FWD WHT 22 ORG
P2

LAMP
COM BLU [-] START BLU 124 N.C. N.O. N.C. N.C.
#1 CORD - FWD - DSB
#2 CORD - REV - DSA REV BLK 24
QCPP +12V RED 123
+12v
#3 CORD - DWN - SSB
#4 CORD - UP - SSA UP GRY 25 VFD to PBB [-] BLK [-]
[-] GND
[-]
DWN PNK 26 LATCH (ELC) WHT [-]
+24v 124 215 216
GND GRN GND
N.O. BRN +24v
TOS LS N.C. WHT SHIELD N/C
102 101
LEFT

23
217

24

Y14
N.C. BLU MODBUS B BLK 3

X4
MODBUS

S13 13
103
P3

14
30 MODBUS A RED 2

S44
N.O. BLK

X1

S14
215
4

S34
MODBUS GND CLR 15

S24

REM
I30E-STOP
I31 START
I32HI PRES
I33LO PRES
FWD

REV

UP

DWN
IDEC

COM
COM
+A1
216

-A2

I34
I35
I36
I37
N.C. BRN
TOS LS N.C. WHT
+24v [-] FC4A-N08B1
RIGHT N.O. BLU 41
+12v 5A 123
14 1 219 213 +24v 90 +12v 210 73 209 207 [-]
P4 N.O. BLK 40
16 2 220

PRX

A2

A1
12

14
11
217 71 208 206
N.O. BRN 30 3 41
HYDRAULIC N.O. WHT [-] +12v 201 203
4 211 214 218
ON P.S. N.O. 1 BLU 51
OPTIONAL
REM STOP

STOP
5 212 [-]

A2

A1
218 200 202 +12v

12

14
11
E-
P5 N.O. 3 BLK +24v OPTIONAL
REM START 6 210
OPTIONAL
204 7 208 10 26 203

OUT
REM FWD

NC

NC

NC
COM

-V

COM1

COM2

COM3
Q0

Q1

Q2
Q3
Q4

Q5
Q6

Q7
N.C. BRN
BOS L.S.

E-STOP
LAMP

E-STOP
OPTIONAL

DWN
205 8 209 11

CR4

FWD

REV

UP

DWN
A2

A1
12

14
11
REM REV
NOT USED WHT
P6

TOS

STOP

PROX

BOS

I7 HYD-ON
[-]

COM
COM
COM
COM
COM
COM BLU +24v

I0
I1
I2
I3
I4
I5
I6
IN
N.O. BLK 63 [-] 25 202 IDEC
FC5A-D16RS1
[-]

CR3

A2

A1

+24v GND
12

14
11

UP
+24V BRN +24v 81 212 63 [-]
HYD FILTERS [-]

[-]
+ -
SERIAL
HI PRES WHT 71 24 201
[-]
P7 COM BLU [-]
83 40 213 51

REV
CR2

A2

A1
+12v 12

14
11
LO PRES BLK 73
+24v

RS485
4

A B SG
+24v 22 200
+12v BRN +24v 3
ENCODER HMT/FWD
81

A2 A2

A1 A1
A WHT +24v
22 12

24 14

21 11

302
CR1 2
[-] BLU [-]
P8 303 +24v
B BLK 83 GND
OUT IN
GND NEW TECH MACHINERY
MATERIAL WEIGHT FINISH
SEE BOM 19.174 lbs CORP.
REV ECR NO. DATE RELEASED BY TOLERANCES DRAWN BY PART NAME
.XX = `.01 CONTROL BOX ASSEMBLY
REVISION
HISTORY

DATE
.XXX = `.005
FRACTION = `1/32"
CHECK BY PART NUMBER SHEET REVISION

ANGLE = `1/2°
DATE
WAV-381-000 2 OF 2 0
 PARTS LIST
25 17 19 18
ITEM QTY PART NUMBER TITLE
29 24
1 1 ELC-110-002 JUMPER, FBS 2-5, RED PN: 3030161
16
2 4 ELC-110-003 END STOP PN: 3022276 28
3 TBD ELC-110-021 FERRULE, 20GA, WHITE (NOT SHOWN)
4 TBD ELC-110-022 FERRULE, 12GA, GRAY (NOT SHOWN) 27
5 TBD ELC-110-023 FERRULE, 16GA, BLACK (NOT SHOWN)
6 TBD ELC-110-024 FERRULE, 18GA, TWIN, RED (NOT SHOWN) 31 30 26
7 2 ELC-110-051 QUATTRO TERMINAL BLOCK PN: 3209578
12
8 2 ELC-110-056 QUATTRO GROUND TERMINAL BLOCK PN: 3209594
9 1 ELC-150-000 TERMINAL BLOCK/RELAY ASSY-VFD
11
10 5ft ELC-180-320 CABLE, 20ga, 3 COND W/ SHIELD
11 1 ELC-180-321 PILOT LIGHT, 22MM, 24V, RED
12 1 ELC-180-322 PILOT LIGHT, 22MM, 12V, GREEN
13 1 ELC-180-336 POWER SUPPLY 3PH TO 12VDC 51
14 1 ELC-180-337 BREAKER - 3PH, 30A
15 1 ELC-180-338 CONTACTOR - 3PH, 1NO, 24VDC COIL
16 1 ELC-180-339 VFD - 15HP, 480VAC, 3PH
17 1 ELC-180-341 DISCONNECT BREAKER PN XTIHU3030AFF000XXX
18 1 ELC-180-342 ROTARY HANDLE BASE PN KXTBRHEBFP
19 1 ELC-180-343 ROTARY HANDLE SHAFT PN KXTARHES500 33 39
20 1 ELC-180-344 DISCONNECT HANDLE PN OHY65J10B
21 1 ELC-180-346 BREAKER, 3PH, 1A PN S203-C1
22 3 ELC-180-348 TERMINAL BLOCK JUMPER, JB8-2
23
24
6
2
ELC-180-349
ELC-180-350
TERMINAL BLOCK, ZK6
LUG KIT, 3 PIECES, KXT1CU
A
25 1 ELC-180-353 AUX CONTACT FOR MAIN BREAKER
26 1 ELC-300-104 SELECTOR SWITCH, W/1 N.O.
27 1 ELC-300-184 GAS/ELC TAG
28 1 ELC-300-185 POWER TAG
29 1 ELC-300-186 FAULT TAG QCPP TO PBB 39
30 2 ELC-400-017 IDEC #HW-C10 N/O CONTACT BLOCK
31 1 ELC-400-018 IDEC #HW-C01 N/C CONTACT BLOCK VFD FROM P10 40
32 1 ELC-400-100 RECEPTACLE, 6 PIN, MALE X 1M
33 1 ELC-400-102 CABLE, 6 PIN, FEMALE x 1M
MODBUS 10 40
34 1 ELC-400-121 1 POLE RELAY, 24VDC 39 38 MAIN POWER IN
2
35 1 ELC-400-122 1 POLE RELAY BASE
36 1 ELC-400-123 2 POLE RELAY BASE 9 14 15 32 QCPP FROM ENGINE
8 23 37 34 13 21
44 43 46 2
37 1 ELC-400-125 2 POLE RELAY, 12VDC 43 39 MOTOR OUT
38 1 ELC-401-097 PLUG MALE, 3Ph, 30A, 480V 2 7 1 22 36 35 50 42 48 44
39 3 ELC-425-023 STRAIN RELIEF, 1/2 NPT, .38/.75
40 2 ELC-450-006 STRAIN RELIEF, 1/2" NPT .10-.30" 45
41 8 FAS-HC5-116 HEX HEAD CAP SCREW 1/4-20 x 7/8" LG
46
42 4 FAS-HC5-124 HEX HEAD CAP SCREW, 5/16-18 x 5/8" LG.
43 4 FAS-NUY-186 NYLOC HEX NUT, #10-32
44 4 FAS-SRM-203 PHILLIPS PAN HEAD SCREW, 10-32 x 1/2"
45 2 FAS-WRF-244 10 RUBBER WASHER
20
46 6 FAS-WSF-344 WASHER, FLAT, #10 SAE 49
47 8 FAS-WSL-252 WASHER, LOCK, 1/4"
48 4 FAS-WSL-256 WASHER, LOCK, 5/16"
49 4 MHW-300-140 DAMPING SANDWICH, 9378K71
50 4 WAV-384-001 VFD MOUNT BAR
51 1 WAV-384-340 ENCLOSURE WITH HOLES
NEW TECH MACHINERY
50 MATERIAL WEIGHT FINISH
NOTE: HOLE DETAIL ON ENCLOSURE DRAWING 9 SEE BOM 69.858 lbs NONE CORP.
TOLERANCES DRAWN BY PART NAME
47 41 REV ECR NO. DATE RELEASED BY
0 PROTO 01/30/2017 AJB .XX = `.01 BT
VFD ENCLOSURE ASSY, 480V
REVISION
HISTORY

DATE
.XXX = `.005 01/13/2017
FRACTION = `1/32"
CHECK BY PART NUMBER SHEET REVISION
AJB
ANGLE = `1/2°
DATE
01/30/2017
WAV-384-000 1 OF 2 1
 GAS (NC) / ELC (NO)
504
GND 403 503 402

L1
L2
L3
STO
N.O. N.O. N.C. N.C. T1 T2 1 2
U U
O O IN IN

[-]
501

A1
A2
A3
[-]
506 11 505 21 11 301 591 592
501 +12v 505 302
506 507 12 GND 22 12 GND
AUX

14 504 24 14 L3 L3 L2 L2 L1 L1 C 503
508 DC DC
VFD
CONTACTOR R2 R1 [-] [-]
NO

GAS MODE POWER

590 A2 A1
VFD - P10 [-]
POWER LAMP FAULT LAMP

E-STOP GAS KILL

R2 X1A X1B
NC 502
[-]
A2 A1 510
R2 12V GREEN 24V RED 1
SCR
2
AI1 GND
3
+10V
4 5
AI2 GND
6 7
AO GND
8 17 18
ROCOMRONC RONO
19

12V COIL
24v COIL
11 12

N.C.
GAS NC ELC NO
506 9 10 11 12 13 14 15 16 20 21 22
+24V GND DCOM DI1 DI2 DI3 DI4 DI5 DOSRCDOOUTDOGND
501
[-] A2 A1 510 [-] A2 A1 502

[-]

C1
C2
C3
N.O.
508 511 512
511

[-]
RED RED

B1
B2
B3
N.C. [-] 512
R1 BLK BLK
11 12
12vdc Power Supply 507
N.C.
N.O.
303 [-] MAINS BRAKE MOTOR
507 U1 V1 W1 BRK+ BRK- U2 V2 W2

A1
A3

A2
N.C.
R1
PBB 503 502 A1 A2 [-] QCPP

G1

G2

G3

W
U

V
N.O.
KILL (GAS) ORG
MAIN DISCON
R1
ORG KILL (GAS) 301 12v RECHARGEABLE
402 START BLU
504 24

N.O.
21 505
BLU START 302 BATTERY
403 +12V RED [-]
508
RED +12V MODBUS
[-] [+]
303 SH B A GND
POWER LAMP [-]
[-] [-] BLK 12V GREEN BLK [-] [-]
WHT WHT LATCH (ELC)
GND GND GRN GRN GND GND +12v [-] [-] 1 3
GND

B1
B2
B3
2 4
510

C1
C2
C3

G1
G2
G3
590
ORG KILL (GAS) GRN GND
BLU START 402 BLK L1
460VAC 3PH
QCPP RED +12V 403 RED L2
[-] [-] WHT L3 POWER IN
VFD to PBB BLK
WHT
GRN GND GND 301 KILL (GAS)
ORG
302 BLU START
VFD CONTACTOR +24V BRN 590
303 RED +12V QCPP
VFD STO OUT1 WHT 591 [-] BLK [-]
STO IN1 BLU 592 QCPP to VFD
P10 WHT N/C
TEMP BLK
GND GRN GND

SHIELD 1
MODBUS B RED 2 GND GRN GND
MODBUS

F1
F2
15HP
F3
MODBUS A BLK 3 U BLK PH1

E1
E3

E2
V RED PH2
MOTOR

E1
E3

E2
MODBUS GND CLR 4
F3
F2
F1

GND W WHT PH3

NEW TECH MACHINERY

MATERIAL WEIGHT FINISH
SEE BOM 69.858 lbs CORP.
REV ECR NO. DATE RELEASED BY TOLERANCES DRAWN BY PART NAME
.XX = `.01 VFD ENCLOSURE ASSY, 480V
REVISION
HISTORY

DATE
.XXX = `.005
FRACTION = `1/32"
CHECK BY PART NUMBER SHEET REVISION

ANGLE = `1/2°
DATE
WAV-384-000 2 OF 2 1
16265E.
33r
dDr
.St
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Aur
ora,
CO8001
1

WAV-MAN | Revision 1 | 09-11-2017