Weh TW232 User manual

WEH®- We Engineer Hightech
Type TW232
Operating instructions ⋅Betriebsanleitung Date: 11/21
WEH®Connector for pneumatic pressure and vacuum tests in
straight tubes and in bores
WEH®Adapter zur pneumatischen Druck- und Vakuumprüfung in
Glattrohren und in Bohrungen

Die deutsche Version ist das Original.
Hersteller: WEH GmbH Verbindungstechnik - im Nachfolgenden „WEH“ genannt.
The German version is the original.
Manufacturer: WEH GmbH Precision Connectors – hereinafter referred to as “WEH”.
LANGUAGES
TYPE TW232� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
WEH®Connector for pneumatic pressure and vacuum tests in straight tubes
and in bores
TYPE TW232 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 30
WEH®Adapter zur pneumatischen Druck- und Vakuumprüfung in Glattrohren
und in Bohrungen
AE
DE

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 11
5. STORAGE 12
5.1 Safety instructions for proper storage 12
5.2 Storage 13
6. REQUIRED TOOLS 13
7. INSTALLATION 14
7.1 Safety instructions for installation 14
7.2 Installation of media line and pilot pressure line 15
7.3 Checking the connection for leak tightness 15
Type TW232
WEH®Connector for pneumatic pressure and vacuum tests in
straight tubes and in bores
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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 16
8.1 Safety instructions for operation 16
8.2 Connection 17
8.3 Disconnection 18
9. INSPECTION | MAINTENANCE 19
9.1 Safety instructions for inspection and maintenance 19
9.2 Maintenance intervals 20
9.3 Overview of minimum intervals for inspection and maintenance 20
9.4 Maintenance 21
10. LUBRICATION 25
10.1 Safety instructions for lubrication 25
10.2 Lubrication 25
11. TROUBLESHOOTING 26
12. DISPOSAL 28
13. ACCESSORIES | SPARE PARTS 28
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1. INTRODUCTION
Dear Customer,
thank you for deciding to use our products.
The WEH®TW232 Connector has been developed for pneumatic pressure and vacuum
tests in straight tubes and in bores.
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 instruc-
tions 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 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 instal-
lation, 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.
- It is assumed that only transport and storage facilities suitable for the storage of the
WEH®Product are used.
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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 WEH®TW232 Connector has been developed for pneumatic pressure and vacu-
um tests in straight tubes and in bores.
ÎOnly use the WEH®Product if you fulfill the following specifications:
- The test piece must have a surface finish of ≤Rz8µm in order to seal under the
specified pressure.
- The max. hardness of the test piece is not allowed to exceed 28HRC in order for
the clamping jaws to grip correctly.
Note: Depending on the hardness of the test piece, clamping jaw marks may appear
in the test piece.
Contact WEH if the application lies outside the specified values or if you have any
questions regarding the surface finish.
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® Connector has been specially developed for your application and require-
ments that you specified when placing your order. The connector 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 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
WEH®TW232 Connector up to sealing range Ø20�0 mm
Pos� Description
1 Base unit
2 Adaptor
3 Clamping jaws
6 Sealing disc
7 Front seal
8 Shaft
10 Spacer
16 Retaining ring for the
clamping jaws
Definition of ports
B1 Media inlet
P1 Pilot pressure supply line
GMounting bore
8
3
6
10
16
7
1
B1
2
P1
G
G
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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.
Characteristics Basic version
Nominal bore (DN) 8.6mm
Max. allowable operat-
ing pressure PS Vacuum up to 70 bar
Pilot pressure 6 - 12 bar
Temperature range +5°C to +80°C
Leak rate 1 x 10-3 mbar x l/s
Max. allowable
surface finish of test
piece
Rz8 µm
Max. allowable
material hardness of
test piece
28 HRC
Part materials Clamping segments: Corrosion resistant stainless steel, hardened
Housing: Anodized aluminium
Sealing materials Front seal in NBR
Actuation Pneumatic actuation
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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 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 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 14.
> 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 the corresponding torque) X
-- Suitable open-ended spanner insert (suitable for the relevant spanner widths and
torque spanner) X
W136538 WEH®O-ring picker set*X
E99-40 WEH®Lubricant X
E99-44923 WEH®Maintenance spray 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 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 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 ports.
ÎPrior to installation, check that the counterparts are designed in accordance with the
assembly data (see Chapter 7.2 Installation of media line and pilot pressure line) speci-
fied for the WEH®Product by WEH.
Note: The indicated assembly data (tightening torques, assembly turns etc.) are values
that apply only to the components delivered by WEH.
ÎConnect the WEH®Connector to a suitable securing device (mechanical connection
via cylinder, rigid fixture, or other means) at the mounting bores “G” on the bottom of
the connector (or other secure fixture) so that the connector is securely connected
to the test piece when pressurized and can not come loose.
For the tightening torque please refer to the table Chapter 7.2 Installation of media
line and pilot pressure line on page 15.
Caution: The safety device must be designed to withstand the loosening force that
occurs (plus an appropriate safety tolerance).
Example of the loosening force: The test piece has an inner diameter of
1/2” (= 12.7 mm) and is tested at a maximum of 5 bar.
Loosening force* = pressure x area 0.5 N/mm2x 12.72x n : 4 = 63.33 N
(* without consideration of friction forces)
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7�2 Installation of media line and pilot pressure line
Please note: Subsequent mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
ÎUnscrew the protection caps from the ports.
ÎWhen mounting the media inlet ‘B1’, hold an open-ended
spanner against the spanner flat A/F(1) (Figure 1).
ÎScrew the ‘B1’ media inlet pressure-tight to the port for the
media line (Figure 1).
For the tightening torque, please refer to the table below.
ÎWhen mounting the pilot pressure line ‘P1’, hold against
the connector.
ÎScrew the pilot pressure port ‘P1’ pressure-tight to the port of the pilot pressure line.
For the tightening torque, please refer to the table below.
Ports Torque
M5 5 Nm ± 10 %
G1/8“ female thread 10 Nm ± 10 %
7�3 Checking the connection for leak tightness
ÎConnect the connector to a closed test piece.
ÎSlowly apply the operating pressure to the connector and media line.
Caution: The test piece must be closed.
ÎCheck the connector, the connection to the media line and the connection to the test
piece for leak tightness.
Attention: Do not use a leak detection spray that contains ammonia, since this could
cause corrosion of the connector.
Figure 1
A/F(1)
B1
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8. OPERATION
8�1 Safety instructions for operation
Please note: Subsequent mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
ÎApply pressure to the WEH®Connector only once it has been connected to a test
piece.
ÎDo not use excessive force when actuating.
ÎFollow the steps in exactly the right order when connecting and disconnecting the
WEH®Connector.
ÎAttach and detach the WEH®Connector only when it is not under pressure.
ÎConnect the WEH®Connector only to test pieces in full working order.
ÎAlign the WEH®Connector correctly with the test piece to prevent damage to the
front seal caused by any sharp edges that the test piece may have.
ÎOnce the connection has been made, gently test the connection by tugging a little
on the test piece to make sure that it is fully engaged and that the clamping jaws are
gripping correctly before introducing the pressurized test medium.
ÎThe clamping jaws of the WEH®Connector are designed to grip the test piece. Keep
fingers and other objects away from the clamping jaws when actuating the connec-
tor.
Caution: Possible consequences of failing to observe this instruction may include:
– Risk of fingers being crushed while connecting and disconnecting
– Risk of personal injury and damage to property by parts that may become
detached under high pressure
– Risk of personal injury by media escaping at high pressure
– Risk to human safety by hoses not being secured
ÎThe WEH®Connector is not fitted with an integrated shut-off valve and thus will not
prevent loss of test medium when disconnecting. Therefore it is important to discon-
nect the connector only under absolutely safe conditions.
ÎThe WEH®Connector is actuated by compressed air. This acts on a piston which col-
lapses the clamping jaws (Pos. 3), allowing them to be connected to the test piece.
ÎMake sure that the test pressure is not built up until the required pilot pressure for
sealing has been removed.
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8�2 Connection
ÎApply pilot pressure to the connector. The clamping jaws
will close together and the connection to the test piece is
possible (Figure 2).
ÎGrip the test piece and plug it up to the stop straight onto
the connector (Figure 3).
Doing so will prevent any damage to the front seal caused
by any sharp edges on the test piece and ensure a correct
connection.
Attention: Insert the test piece carefully and not with force
onto the connector.
ÎVent the pilot pressure line. The test piece tightens itself to
the connector and creates a pressure-tight connection.
Attention: Make sure that the clamping jaws on the test
piece grip correctly, that the connector is seated prop-
erly (the test piece must not wobble) and that the pres-
sure-tight connection has been made. Only then is the
connector connected correctly. Otherwise the test piece
may spring out of place and medium may escape.
ÎPull lightly on the test piece (red arrow Figure 4)
in the direction opposite that of the connection to make
sure that the connector is firmly in place.
- The connector is now connected pressure-tight to the test
piece.
ÎTo start the testing procedure, apply pressure to media
inlet ‘B1’.
Figure 3
Figure 2
Figure 4
pull backwards
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8�3 Disconnection
ÎAfter the end of the testing procedure, fully vent the media
line.
Caution: First depressurize the system before releasing
the connection. The integrated safety system will not let
you open the pressure-aided clamping jaws when the
system is pressurized.
ÎPressurize the pilot pressure line. The clamping jaws
(Pos. 3) close together, the connection to the test piece
is released and the test piece can be removed straight
backwards (Figure 5 and Figure 6).
Attention: In the event that you cannot remove the test
piece from the connector:
- Wait a few moments
- Never use excessive force
- Do not use any tools (e.g. hammer)
- Make sure that the operating pressure is completely
relieved
Figure 6
Figure 5
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9. INSPECTION | MAINTENANCE
Please note: Subsequent mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
Attention: If damage to the WEH®Product or restrictions to its functionality are detect-
ed, measures as set out in Chapter 11. Troubleshooting on page 26 must be taken.
Damaged or leaking WEH®Products must be sent to WEH for maintenance.
9�1 Safety instructions for inspection and maintenance
- The WEH®Product must be depressurized and dismantled for maintenance work.
ÎCheck the WEH®Product for leakage after maintenance work. Please refer to Chapter
7. Installation on page 14.
- For inspection purposes, it is not necessary for the WEH®Product to be dismantled,
but it must be depressurized.
ÎOnly use original WEH®Spare parts. These are exactly suited to the intended applica-
tion and subject to strict quality controls.
ÎDo not damage sealing surfaces or sealing components.
ÎBefore reassembling; check the components, threads and, if present, the sealing
surfaces for damage and contamination. Should you find any damage, replace the
WEH®Product or send it to WEH for maintenance. Stop using the WEH®Product
immediately.
ÎAssemble the WEH®Spare parts absolutely free of oil, grease and dust.
ÎBefore each reassembly, clean the WEH®Product and the corresponding
components by blowing off with oil-free compressed air and remove any adhering
dirt using a damp, soft and lint-free cloth.
Do not use solvents. Use only clean water as cleaning agent.
Attention: Only use oil-free compressed air to blow off the dirt.
Note: Make sure that no cleaning agent enters the gas channel.
ÎObserve the specified tightening torques during maintenance.
ÎApply pressure to the WEH®Product only once it has been connected to a test piece.
For leak tests, connect the WEH®Product to a closed test piece (see Chapter 7. Instal-
lation on page 14).
Attention: If you apply pressure to the WEH®Product without the test piece connected,
the WEH®Product may be damaged. Therefore always use a test piece.
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9�2 Maintenance intervals
ÎInspect the WEH®Product at regular intervals depending on the respective operating
conditions, but at least every 3 months. After 20,000 cycles or 3 years at the latest,
depending on what happens first, starting from the date of delivery (invoice/ goods
issue date by WEH or the distributor), the WEH®Product must be sent to WEH for
maintenance.
These intervals can also be significantly shorter, which depends especially on your
individual application/use. Therefore, in case of abnormalities – especially during
regular inspection – send the WEH®Product immediately to WEH for maintenance.
If the WEH®Product is not regularly inspected and sent to WEH for maintenance,
leakage may occur and under certain circumstances this may result in failures and/
or accidents.
9�3 Overview of minimum intervals for inspection and maintenance
No� Inspection
Initial
(before com-
missioning
for the 1st
time)
Daily Weekly
1Check front seal for damage and dirt
accumulation X X
2 Check exterior for damage and dirt X X
3Check clamping jaws for damage and
correct functioning X X
4Check connector and media line for
leakage (see Chapter 7. Installation)X X
No� Maintenance After every
1,000 cycles Monthly After 3 years or 20,000 cycles*
5
Replace the front seal
(see Chapter 9.4.1 Replacement of front
seal (pos. 7)) X
6Lubricate the connector
(see Chapter 10. Lubrication)X
7Return to WEH for in-factory mainte-
nance X
* depending on what happens first
Note: Component arrangement see Chapter 3. Product overview / product description on
page 10.
ÎIf your application requires, set shorter intervals thanindicated above. A significant
shortening of the minimum intervals is particularly necessary if abnormalities are
found during the inspections.
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