Weh TK16 H2 User manual

WEH®- We Engineer Hightech
Type TK16 H2
Operating instructions ⋅Betriebsanleitung Date: 09/22
WEH®Hydrogen fueling nozzle
WEH®Füllkupplung zur Wasserstoffbetankung

Die deutsche Version ist das Original.
Hersteller: WEH GmbH Gas Technology - im Nachfolgenden „WEH“ genannt.
The German version is the original.
Manufacturer: WEH GmbH Gas Technology - hereafter referred to as 'WEH'.
LANGUAGES
TYPE TK16 H2� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
WEH®Hydrogen fueling nozzle
TYP TK16 H2� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 42
WEH®Füllkupplung zur Wasserstoffbetankung
AE
DE

Type TK16 H2
WEH®Hydrogen fueling nozzle
CONTENTS
1. INTRODUCTION 6
1.1 For your guidance 6
1.2 General information 7
1.3 Warranty and liability 7
1.4 General safety instructions 8
1.5 Definition of qualified personnel 9
2. INTENDED USE 9
3. PRODUCT OVERVIEW / PRODUCT DESCRIPTION 10
4. TECHNICAL DATA 13
5. STORAGE 16
5.1 Safety instructions for proper storage 16
5.2 Storage 17
6. REQUIRED TOOLS 18
7. INSTALLATION 19
7.1 Safety instructions for installation 19
7.2 Installing the filling and venting hose 20
7.3 Checking the connection for leak tightness 20
7.4 Connection of data cable (only TK16 H2with IR) 21
7.5 Check of data interface function (Pos. 1) 21
7.6 Fitting the protective sleeve (Pos. 5) 21
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The German version is the original.
Manufacturer: WEH GmbH Gas Technology - hereafter referred to as 'WEH'.
8. OPERATION 22
8.1 Safety instructions for operation 22
8.2 Connecting 22
8.3 Disconnection 23
9. INSPECTION | MAINTENANCE 24
9.1 Safety instructions for inspection and maintenance 24
9.2 Maintenance intervals 25
9.3 Overview of minimum intervals for inspection and maintenance 26
9.4 Maintenance 27
10. LUBRICATION 32
10.1 Safety instructions for lubrication 32
10.2 Lubrication 32
11. CHECKING THE LEAK RATE 33
11.1 Measuring the leak rate using a concentration meter 33
11.2 Safety instructions for connecting the service receptacle 34
11.3 Checking the leak rate 34
12. EXAMINATION AFTER SEPARATION 36
13. TROUBLESHOOTING 37
14. DISPOSAL 39
15. ACCESSORIES | SPARE PARTS 39
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1. INTRODUCTION
Dear Customer,
Thank you for deciding to use our products.
The WEH®TK16 H2Fueling nozzle was specifically developed for quick refueling
vehicles with compressed gaseous hydrogen (CGH2).
Observe and follow all instructions and warnings in these operating instructions�
Non-observance may result in personal injury and/or property damage�
1�1 For your guidance
The markings and symbols contained in these operating instructions have the following
meanings:
- Items are indicated by a dash
ÎCalls for action are indicated by an arrow
Figures
The illustrations and/or images used in these operating instructions are particularly provided
for illustrative purposes only and may differ in some details from the actual product. For
binding information, please refer to your individual orders.
Abbreviations / Definitions
For explanation of abbreviations and definitions of terms see applicable Technical
Appendix of the corresponding catalog or www.weh.com
Definition of signal words
Caution: A section marked with 'Caution' warns you about hazards that could result in a
slight, usually reversible personal injury if you do not comply with this instruction.
Attention: Sections marked ‘Attention’ warn you of situations that could lead to property
damage and disruptions in operation if you do not comply with the instruction.
Note: Sections marked ‘Note’ indicate that malfunctions in operation may occur if you
do not comply with the instruction.
Please note: Sections marked with ‘Please note’ provide you with additional information
for smooth operation.
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1�2 General information
ÎFirst read these operating instructions to avoid misuse and resulting damage.
- In these operating instructions you will find all the necessary information and
instructions for the WEH®Product.
ÎThen check the contents of your delivery. Each delivery must contain:
- a delivery note
- an original WEH Test report (not applicable to spare parts)
- WEH operating instructions
ÎIf any documents are missing, please contact WEH or your responsible distributor.
1�3 Warranty and liability
- Our General Terms and Conditions apply.
ÎRead these operating instructions and safety instructions carefully andfollow the
information contained therein.
- The information in these operating instructions reflects to the state of knowledge at
the time of printing. Failure to comply may void the warranty. Any side agreements
to these operating instructions require the written approval of the Head of the Quality
Department at WEH.
- Violation of these operating instructions result in the lapse of all warranty claims.
WEH will accept no liability for consequential damage, in particular damage due to
personal injury and/or other legal interests.
Caution: WEH®Products may only be repaired by WEH.
ÎContact WEH or the responsible distributor if the WEH®Product requires mainte-
nance. Special maintenance work that may be performed by the operator is described
in these operating instructions and is specially marked.
ÎOnly use original WEH®Spare parts. These are exactly suited to the intended appli-
cation and subject to strict quality controls.
- You yourself are solely responsible for the proper performance of the replacement or
repair. WEH is not responsible for the performance or any damage and/or losses aris-
ing from it. WEH assumes no guarantee, warranty, product liability or other liability
for any replacement or repair of the WEH®Product performed by you or a third party.
If you or a third party does not have the necessary skills and qualification for proper
performance, you must refrain from performing replacement or repair. Otherwise,
there is a particular risk of endangering yourself and third parties.
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1�4 General safety instructions
ÎAlways comply with all applicable local, national and international requirements,
stipulations, decrees, laws, standards, provisions, directives, norms, regulations,
prohibitions and instructions as well as all applicable industrial, quality and technical
standards. In particular, make sure that you and all users comply with the applicable
requirements related to occupational health and safety as well as product safety
requirements and that all required permissions, certificates and approvals have been
obtained.
ÎThese operating instructions should be provided to anyone responsible for the
installation, operation and maintenance of this WEH®Product.
- The WEH®Product and these operating instructions are intended for use by
qualified personnel (see Chapter 1.5). Make these operating instructions available
in particular to the qualified personnel responsible for the individual phases of the
life cycle (especially for storage, installation, operation, inspection and mainte-
nance, troubleshooting and disposal) of the WEH®Product. The qualified personnel
must have read and understood these operating instructions.
ÎContact WEH before using the WEH®Product if the instructions in these operating
instructions are unclear in any way.
ÎTake appropriate safety measures if operating conditions exist that could endanger
the user.
ÎIn case of any damage that may affect the proper functioning of the WEH®Product, do
not use the WEH®Product until the situation has been clarified. Disassembly of the
WEH®Product may only be performed by WEH.
ÎComply with the assembly data indicated in these operating instructions. Tightening
with higher torques/assembly turns can result in damage or even fractures when the
system is pressurized.
ÎDo not use any auxiliary materials or cleaning agents other than those indicated in
these operating instructions. Using other auxiliary materials or cleaning agents may
cause damage to the WEH®Product or to downstream components.
- WEH is not responsible for damage caused by external forces or other external
influences.
- Proper transport and storage of the WEH®Product is assumed.
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ÎDo not apply any external forces to the WEH®Product. Therefore, do not lean on the
(connected) WEH®Product, do not hang on the WEH®Product and do not climb on
the WEH®Product under any circumstances. In addition, refrain from hammering
on the WEH®Product or similar. Such force effects can lead to damage to property
and personal injury. Also make sure that the WEH®Product is protected from being
stepped on or run over in any way.
- The WEH®Product can become very hot or very cold due to the possible fluids
flowing through it, depending on the application and operating situation. In this
regard, observe the national and international regulations on occupational health
and safety to prevent injuries.
1�5 Definition of qualified personnel
- Qualified personnel, as defined by these instructions, are persons who, based on
their professional training, their knowledge (including the relevant standards and
regulations), experience and manual skills, can independently assess and properly
perform assigned work tasks (in conjunction with WEH®Products) and can thus
independently recognize and prevent potential dangers at an early stage.
2. INTENDED USE
- The WEH®TK16 H2Fueling nozzle was specifically developed for quick refueling
vehicles with compressed gaseous hydrogen (CGH2).
- When used at sea or in the vicinity of the sea, increased salt and moisture content of
the air may cause faster wear and corrosion of the product. Please observe the spe-
cial maintenance instructions in Chapter 9.2 Maintenance intervals on page 25.
ÎAlways ensure that the WEH®Product is used only within the range of its intended
use. Please note in particular the technical data of the WEH®Product in Chapter 4 as
well as the marking on the WEH®Product itself.
- This WEH®Product is generally classified as pressure accessory in accordance
with Article 2 (5) of the Pressure Equipment Directive 2014/68/EU and is consid-
ered to be similar to piping. This WEH®Product may not be used as safety acces-
sory. Furthermore, it is pointed out, that this WEH®Product is designed and placed
on the market in accordance with the requirements of Article 4 (3) of the Pressure
Equipment Directive 2014/68/EU. The assessment with regard to a different classi-
fication can, however, be made on request.
Caution: Any use beyond the scope of application is considered as unintended use
and may result in personal injury and/or property damage.
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3. PRODUCT OVERVIEW / PRODUCT DESCRIPTION
Product overview - WEH®TK16 H2Fueling nozzle
TK16 H2TK16 H2with IR*TK16 H2High-Flow TK16 H2High-Flow
with IR*
Series Car TRUCK Pressure range Part no�
25 MPa 35 MPa
TK16 H2
X X C1-45695-X4-X01
X X C1-45696-X5-X01
TK16 H2with IR*X X C1-103471-X01(ATEX)
TK16 H2High-Flow X X C1-85042-X01
TK16 H2High-Flow with
IR*X X C1-94315-X01 (ATEX)
*IR = infrared data interface
Overview of Pressure Stage/Coding
Overview Receptacle TN1 H2
TN1 H2for IR*
TN1 H2High-Flow
TN1 H2High-Flow
for IR*
TN1 H270 MPa
TN1 H270 MPa
for IR*
Fueling nozzle Pressure PN 25 MPa 35 MPa 35 MPa 70 MPa
TK16 H2
25 MPa X X X X
35 MPa X X X
TK16 H2with IR*35 MPa X X X
TK16 H2High-Flow 35 MPa X
TK16 H2High-Flow
with IR*35 MPa X X
*IR = infrared data interface
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Product description
TK16 H2/ TK16 H2High-Flow
Pos� Description
1Guide bush with
impact protection
2 Cover disc
3 Actuation lever
4 Countersunk screw (3x)
5 Protective sleeve
6 Swivel joint 360°
Definition of ports
B1 Media inlet
C2 Gas recirculation
4
6
1
23
5
B1
C2
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TK16 H2with IR / TK16 H2High-Flow with IR
Pos� Description
1Guide bush with impact protec-
tion and data interface
2 Cover disc
3 Actuation lever
4 Countersunk screw (3x)
5 Protective sleeve
6 Swivel joint 240°
7 Data cable
Definition of ports
B1 Media inlet
C2 Gas recirculation
4
6
1
23
5
B1
C2
7
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4. TECHNICAL DATA
Please note: Depending on the application, the technical data of your WEH®Product
may differ from these operating instructions. Please therefore observe the marking on
the WEH®Product itself.
TK16 H2/ TK16 H2High-Flow
Characteristics Basic version
Nominal bore (DN) 8 mm
Pressure range PN = 25 MPa | PS = 35 MPa
PN = 35 MPa | PS = 45 MPa
Media temperature
range -20 °C to +85 °C
Ambient temperature
range -40 °C to +85 °C
Parts materials Wear-resistant stainless steel, corrosion-resistant surfaces
Sealing material Hydrogen-resistant
Nozzle type Type A acc. to SAE J2600:2015 and previous resp.
ISO 17268:2012 and previous
Design Thermally insulating plastic casing and gas recirculation
Weight Approx. 1.8 kg
Conformities /
Tests /
Approvals
- SAE J2600:2002
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TK16 H2with IR / TK16 H2High-Flow with IR
Characteristics Basic version
Nominal bore (DN) 8 mm
Pressure range PN = 35 MPa | PS = 45 MPa
Media temperature
range -20 °C to +85 °C
Ambient temperature
range -40 °C to +85 °C
Parts materials Wear-resistant stainless steel, corrosion-resistant surfaces
Sealing material Hydrogen-resistant
Nozzle type Type A acc. to SAE J2600:2015 and previous resp.
ISO 17268:2012 and previous
Design With plastic thermal protection, gas recirculation and data interface
acc. to SAE TIR J2799 protocol
Weight Approx. 2.4 kg
Conformities /
Tests /
Approvals
Fueling nozzle:
- SAE J2600:2002
IR data interface:
- SAE TIR J2799
- ATEX
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Data interface
Characteristics Basic version
Signal input format J2799
Signal output format RS485
Sensitivity level 0.57 - 0.060 A/W
Band width 870 - 950 nm
Mains voltage 5 V DC
Minimum voltage 3.7 V
Allowable current 20 mA
Allowable power
Supply voltage 16 V
Data voltage 0 - 5.5 V
Output voltage level 0 - 6 V
Protection class IP66
Pin assignment of connector on the data cable
Connector Color Signal
1 Brown 5 V DC voltage
2 Blue 5 V DC ground
3 White RD 458 Data +
4 Black RD 458 Data -
42
13
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5. STORAGE
5�1 Safety instructions for proper storage
ÎMake sure that you always comply with these following safety instructions and stor-
age time.
Attention: Improper storage of the WEH®Product can significantly reduce the maxi-
mum service life.
ÎProtect the WEH®Product against damage, contamination, inappropriate storage
and excessive temperature fluctuations.
ÎStore the WEH®Product, the accessories and spare parts in the original packaging
until they are used for the first time and during periods when they are not being used.
ÎStore the WEH®Product within a temperature range of -40 °C up to +40 °C. Storage
temperatures outside this range may affect the service life of the WEH®Product.
ÎDo not store the WEH®Product in the vicinity of heat sources. Avoid humidity and
condensation. The ideal relative air humidity for storage is approx. 65%.
ÎDo not store the WEH®Product together in the same space with solvents, chemicals,
acids, fuels or disinfectants.
ÎProtect the WEH®Product against light, in particular direct sunlight, oxygen, ozone,
heat, UV radiation, and other negative environmental influences. The service life of
parts made of elastomer or plastic may be substantially reduced by such environ-
mental factors.
ÎDo not stack WEH®Products. For storage and retrieval, follow the first-in-first-out
(FIFO) principle.
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5�2 Storage
ÎFollow the safety instructions in Chapter 5.1 and observe the following storage
times. The allowable storage time is valid from the date of delivery (invoice/goods
issue date from WEH or the distributor) on the label of the packaging. If the
WEH®Product is installed in a complete system, the storage time depends on the
component with the shortest storage time.
Up to 3 years
ÎBefore use, check the surfaces of the external seals for cracks.
Attention: Any elastomer seals with fine cracks on the surface must
be replaced.
Note: If you should have any doubts about the aging state of the
stored WEH® Product, please contact WEH.
Attention: Before commissioning, check the WEH® Product for leak
tightness. On this topic, see Chapter 7. Installation on page 19.
> 3 years - Before use, all elastomer seals must be replaced.
ÎFor this, send the WEH®Product to WEH for maintenance.
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6. REQUIRED TOOLS
Part No� Description Installation Checking the
leak rate
Mainte-
nance &
Lubrication
C1-148079 WEH®TNS1 H2Service
receptacle X X
WKZ-148012 WEH®Assembly tool X X
-- Open-ended wrench A/F16 X X
-- Open-ended wrench A/F19 X X
-- Calibrated torque wrench
(suitable for corresponding torque) X X
-- Open-ended wrench A/F16
(suitable for the torque wrench) X X
-- Open-ended wrench A/F19
(suitable for the torque wrench) X X
-- Hex bit A/F2.5
(suitable for the torque wrench) X X
-- Hexagonal
screwdriver A/F2.5 X X
-- Slotted screwdriver X
-- Open-ended wrench A/F14 X
-- Open-ended wrench A/F14
(suitable for the torque wrench) X
-- Vice with plastic jaws X
E99-90160 WEH®Threadlocking adhesive X
E99-35 WEH®Adhesive X
E99-9 WEH®Degreasing spray X
E99-44923 WEH®Maintenance spray X
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7. INSTALLATION
Please note: Subsequent mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
7�1 Safety instructions for installation
ÎCheck the information provided in these operating instructions and the label on the
WEH® Product. The information must conform to your application.
ÎOnly connect the WEH®Product to faultless connections.
ÎCheck the WEH®Product for transport damages, contamination and other damage. If
you should detect anything wrong with the WEH®Product, it may no longer be used.
Replace the WEH®Product or send it to WEH for maintenance.
ÎRemove transport securing devices (such as protection caps) before installing the
WEH®Product. Transport locks are designed to protect the product and the
connections during transport and storage. The transport securing devices are not,
for example, designed to withstand pressure or to be used as plugs.
ÎEnsure that the system is depressurized. Installation must only be effected in de-
pressurized condition.
ÎBefore installation, check if the counterparts are designed to withstand the assembly
data (see Chapter 7. Installation) that WEH determined for this WEH®Product.
Note: The assembly data (torques, assembly turns etc.) are values which apply exclu-
sively to the components delivered by WEH.
ÎBefore commissioning, make sure that the used hoses and the breakaway coupling
are also suitable for the application (e.g. filling with cryogenic medium).
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7�2 Installing the filling and venting hose
ÎUnscrew the three countersunk screws (Pos. 4) for the
protective sleeve (Pos. 5) using an Allen key A/F2.5.
Remove the protective sleeve and pull it over the filling and
venting hose that has been laid out ready.
ÎUnscrew the protection caps from the connection ports.
ÎWhen mounting the filling and venting hose, hold an
open-ended wrench against the wrench size A/F(1) and
A/F(2) (Figure 1).
ÎScrew the media inlet ‘B1’ pressure-tight onto the connection port of the filling hose
(Figure 1).
Please see the table below for the tightening torque.
ÎScrew the gas recirculation ‘C2’ pressure tight onto the connection port of the vent-
ing hose (Figure 1).
Please see the table below for the tightening torque.
Ports Torque
M12x1.5 male thread 20 Nm +10%
UNF 7/16“-20*male thread 20 Nm +10%
UNF 9/16“-18*male thread 40 Nm +10%
*acc. to SAE J514, 37°
ÎPlease note the connection size marked on your product
- Other connection port sizes available on request
7�3 Checking the connection for leak tightness
ÎConnect the fueling nozzle to the WEH®Service receptacle.
ÎSlowly apply the operating pressure to the filling hose and the fueling nozzle.
ÎCheck the fueling nozzle and the connection between the filling hose and the
fueling nozzle for leak tightness. Please refer to Chapter 11. Checking the leak rate
on page 33.
Figure 1
A/F(1)
B1
C2
A/F(2)
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