Weh CLICKMATE TW154 User manual

WEH®- We Engineer Hightech
CLICKMATE®TW154
Operating instructions ⋅Betriebsanleitung
Quick connector for filling of breathing air bottles
Schnelladapter zum Füllen von Atemluftflaschen

Die deutsche Version ist das Original.
Hersteller: WEH GmbH Verbindungstechnik - im Nachfolgenden „WEH“ genannt.
LANGUAGES
CLICKMATE®TW154 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
Quick connector for filling of breathing air bottles
CLICKMATE®TW154 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
Schnelladapter zum Füllen von Atemluftflaschen
AE
DE
The German version is the original.
Manufacturer: WEH GmbH Precicion Connectors – hereinafter referred to as “WEH”.

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 14
5.1 Safety instructions for proper storage 14
5.2 Storage 15
6. REQUIRED TOOLS 15
7. INSTALLATION 16
7.1 Safety instructions for installation 16
7.2 Installation of the CLICKMATE® TW154 on a filling hose 17
7.3 Installation of the CLICKMATE® TW154 FL with the adaptor W30225 18
7.4 Installation of the CLICKMATE® TW154 FL with the adaptor W30124 19
7.5 Installation of the CLICKMATE® TW154 FL with the adaptor W35631 20
7.6 Installation of the weight and height compensation system TZ100 21
7.7 Checking the connection for leak tightness 21
CLICKMATE®TW154
Quick connector for filling of breathing air bottles
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Operating instructions
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The German version is the original.
Manufacturer: WEH GmbH Precision Connectors - hereafter referred to as 'WEH'.
8. OPERATION 22
8.1 Safety instructions for operation 22
8.2 Connection 23
8.3 Disconnection 24
9. INSPECTION | MAINTENANCE 25
9.1 Safety instructions for inspection and maintenance 25
9.2 Maintenance intervals 26
9.3 Overview of minimum intervals for inspection and maintenance 27
9.4 Maintenance 29
10. LUBRICATION 30
10.1 Safety instructions for lubrication 30
10.2 Lubrication 30
11. TROUBLESHOOTING 31
12. DISPOSAL 33
13. ACCESSORIES | SPARE PARTS 33
13.1 Accessories for the filling hose adapters 33
13.2 Accessories for the filling bar adapters 34
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1. INTRODUCTION
Dear Customer,
Thank you for deciding to use our products.
The CLICKMATE®TW154 for 200 bar and 300 bar was developed for filling breathing air
bottles for direct connection to the filling hose or to existing filling bars (can only be
used with weight and height compensation).
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
For explanation of abbreviations and definitions of terms see 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.
ÎPlease read these operating instructions and safety instructions carefully and follow
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
maintenance. 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
application 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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Operating instructions AE

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.
Caution: Incorrect application poses a risk to the user's health and can cause property
damages. The consequences of incorrect application could include the following:
- the connector or parts of the connector become loose under pressure
- media that may be under pressure, hot or toxic, can escape
- connection hoses vibrate dangerously
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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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 CLICKMATE®TW154 was developed for filling breathing air bottles for direct
connection to the filling hose or to existing filling bars (can only be used with weight
and height compensation). The connector comes in many different sizes and forms.
ÎUse the CLICKMATE®TW154 FL only for filling breating air bottles on existing filling
bars.
ÎUse the CLICKMATE®TW154 FS only for filling breating air bottles with filling hoses.
- The WEH®Connector is not suitable for emptying gas cylinders under pressure.
ÎAlways ensure that the WEH®Product is used only for 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® Connector has been specially developed for your application and
requirements that you specified when placing your order. The connection only works
properly together with your connection and may only be attached to this connection.
- 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
considered to be similar to piping. This WEH®Product may not be used as safety
accessory. 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 classification 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
CLICKMATE® TW154 FL for direct connection to the existing filling bar
Pos� Description
1 Bail actuation
3 Front part
4 Adjustment screw
5 Safety peg
7 Front seal
8Locking lever
(200 bar black, 300 bar red)
9 Fastening screw
Definition of ports
B1 Media inlet
B1
3
7
1
8
95
4
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CLICKMATE® TW154 FS for direct connection to the filling hose
Pos� Description
1 Bail actuation
3 Front part
4 Adjustment screw
5 Safety peg
7 Front seal
8Locking lever
(200 bar black, 300 bar red)
9 Fastening screw
Definition of ports
B1 Media inlet
4
B1
1
7
8
3
9
5
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CLICKMATE® TW154 IS for direct connection to the filling hose of double bottle
systems
Pos� Description
1 Actuation lever
3 Front part
4 Adjustment screw
5 Safety peg
7 Front seal
8Locking lever
(200 bar black, 300 bar red)
9 Fastening screw
10 Swivel joint
Definition of ports
B1 Media inlet
95
B1
3
7
8
1
10
4
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CLICKMATE® TW154 IS for direct connection to the filling hose of double bottle
systems
Pos� Description
1 Actuation lever
3 Front part
4 Adjustment screw
5 Safety peg
7 Front seal
8Locking lever
(200 bar black, 300 bar red)
9 Fastening screw
10 Swivel joint
Definition of ports
B1 Media inlet
95
B1
3
7
8
1
10
4
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.
Characteristics Basic version
Pressure range PN = 200 bar | PS = 250 bar*
PN = 300 bar | PS = 375 bar*
Temperature range +5°C to +70°C
Medium Breathing air (compressed air)
ConnectionA
(cylinder valve) Standard threaded connection for G5/8” female thread (DIN 477)
Inlet B1 Depending on the connection on the filling bar /
adaptor depending on the connection for filling hose
Part materials Wear-resistant stainless steel, corrosion-resistant surfaces, brass
Sealing material FKM / NBR
Actuation Manual actuation via bail
*Please observe the pressure limits specified in the relevant cylinder valve standard. These values may be lower than the
max. allowable operating pressure of the WEH®Product.
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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
storage time.
Attention: Improper storage of the WEH®Product can significantly reduce the
maximum 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
environmental 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 appropriate storage period applies from the date of delivery (i.e. the date
of invoicing or goods issue date as recorded by WEH or its distributor). 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 16.
> 3 years - Before use, all elastomer seals must be replaced.
ÎFor this, send the WEH®Product to WEH for maintenance.
6. REQUIRED TOOLS
Part no� Description Installation Maintenance &
Lubrication
-- Suitable open-ended spanner
(suitable for the relevant spanner widths) X
-- Calibrated torque wrench
(suitable for corresponding torque) X
-- Small slotted screwdriver X
W136538 WEH®O-ring picker set*X
E99-10 WEH®Lubricant X
*The WEH® O-ring picker is manufactured from plastic and has to be considered as a
consumable product.
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7. INSTALLATION
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 connection ports.
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 securing devices serve the purpose of protecting the
product and connection ports 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
depressurized condition.
ÎAvoid using excessively short media lines and narrow bending radii. Lateral forces
may cause leakages or damage to components and make it more difficult to attach
the WEH®Connector properly.
ÎUse arrestor cables, partitions, etc. for additional safety where being used for
hazardous applications or under hazardous conditions.
ÎUSIT rings should be used to seal the cylindric ports.
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 indicated assembly data (tightening torques, assembly turns etc.) are values
that apply only to the components delivered by WEH.
ÎPosition the WEH®Product in your system so that the red marking on the
front part (Pos. 3) is visible. This must be visible for the operator.
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7�2 Installation of the CLICKMATE® TW154 on a filling hose
Please note: Subsequent mentions of descriptions and position numbers refer to
following illustrations on Chapter 7. Installation.
ÎUnscrew the protection cap from the port.
ÎWhen mounting media hose line, hold an open-ended
spanner against the spanner flat AF(1) (Figure 1).
ÎScrew the "B1" media inlet pressure-tight to the port for
the media hose line (Figure 1).
For the tightening torque, please refer to the table below.
Connection Torque
M16x1.5 male thread 20 Nm ± 2 Nm
ÎPlease note the connection size marked on your product.
- Other connection sizes are available on request.
Figure 1
A/F(1)
B1
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7�3 Installation of the CLICKMATE® TW154 FL with the adaptor W30225
ÎUnscrew the existing screw filling connection from the filling bar.
ÎPremount the adaptor (Pos. 14).
ÎPut the union nut (Pos. 12) onto the adaptor (Pos. 14).
ÎInsert the O-ring (Pos. 15) into the appropriate groove of the adaptor (Pos. 14).
ÎScrew the adaptor (Pos. 14) completely into the filling bar.
Tightening torque 20 Nm ± 2Nm
ÎLightly grease the O-ring (Pos. 13) with WEH®Lubricant part no. E99-10 and then
insert it into the plan recess of the adaptor (Pos. 14).
ÎScrew the union nut (Pos. 12) onto the operating media inlet “B1” of the adapter.
Note: The bail of the adapter must be aligned horizontally.
ÎTighten the union nut (Pos. 12). While tightening, hold the wrench size A/F(1) of the
adapter.
For the tightening torque, please refer to the table below.
Connection Torque
Union nut 20 Nm ± 2 Nm
M16x1.5 male thread 20 Nm ± 2 Nm
ÎPlease note the connection size marked on your product.
- Other connection sizes are available on request.
11
13
12
14
15
B1
Pos� Description
11 CLICKMATE®TW154
12 Union nut
13 O-ring
14 Adaptor
15 O-ring
Definition of ports
B1 Media inlet
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7�4 Installation of the CLICKMATE® TW154 FL with the adaptor W30124
ÎUnscrew the existing screw
filling connection from the filling bar.
ÎPremount the adaptor (Pos. 14).
ÎPut the union nut (Pos. 12) and the counter hexagon nut (Pos. 16) onto the
adaptor (Pos. 14).
ÎLightly grease the O-ring (Pos. 15) with part no. E99-10 and then insert it into the rear
plan recess of the adaptor (Pos. 14).
ÎScrew the adaptor (Pos. 14) completely into the filling bar.
Tightening torque 20 Nm ± 2Nm
ÎTighten the counter hexagon nut (Pos. 16).
ÎLightly grease the O-ring (Pos. 13) with WEH®Lubricant part no. E99-10 and then
insert it into the plan recess of the adaptor (Pos. 14).
ÎScrew the union nut (Pos. 12) onto the operating media inlet “B1” of the adapter.
Note: The bail of the adapter must be aligned horizontally.
ÎTighten the union nut (Pos. 12). While tightening, hold the wrench size A/F(1) of the
adapter.
For the tightening torque, please refer to the table below.
Connection Torque
Union nut 20 Nm ± 2 Nm
M16x1.5 male thread 20 Nm ± 2 Nm
ÎPlease note the connection size marked on your product.
- Other connection sizes are available on request.
11
13
16 12
14 15
B1
Pos� Description
11 CLICKMATE®TW154
12 Union nut
13 O-ring
14 Adaptor
15 O-ring
16 Counter hexagon nut
Definition of ports
B1 Media inlet
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7�5 Installation of the CLICKMATE® TW154 FL with the adaptor W35631
ÎUnscrew the existing screw filling connection from the filling bar.
ÎPremount the adaptor (Pos. 14).
ÎPut the union nut (Pos. 12) onto the adaptor (Pos. 14).
ÎPut the customer-side plane sealing onto the adaptor (Pos. 14). WEH recommends
the use of USIT rings.
ÎScrew the adaptor (Pos. 14) completely into the filling bar.
Tightening torque 20 Nm ± 2Nm when using a USIT ring.
ÎLightly grease the O-ring (Pos. 13) with WEH®Lubricant part no. E99-10 and then
insert it into the plan recess of the adaptor (Pos. 14).
ÎScrew the union nut (Pos. 12) onto the operating media inlet “B1” of the adapter.
Note: The bail of the adapter must be aligned horizontally.
ÎTighten the union nut (Pos. 12). While tightening, hold the wrench size A/F(1) of the
adapter.
For the tightening torque, please refer to the table below.
Connection Torque
Union nut 20 Nm ± 2 Nm
M16x1.5 male thread 20 Nm ± 2 Nm
ÎPlease note the connection size marked on your product.
- Other connection sizes are available on request.
Pos� Description
11 CLICKMATE®TW154
12 Union nut
13 O-ring
14 Adaptor
Definition of ports
B1 Media inlet
11
13
12
14
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