Weh TW241 User manual

WEH®- We Engineer Hightech
Type TW241
Operating instructions ⋅Betriebsanleitung
WEH®Connector for pressure and vacuum tests of straight tubes
WEH®Adapter zur Druck- und Vakuumprüfung von Glattrohren

Die deutsche Version ist das Original.
Hersteller: WEH GmbH Verbindungstechnik - im Nachfolgenden „WEH“ genannt.
LANGUAGES
TYPE TW241 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
WEH®Connector for pressure and vacuum tests of straight tubes
TYP TW241 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 42
WEH®Adapter zur Druck- und Vakuumprüfung von Glattrohren
AE
DE
The German version is the original.
Manufacturer: WEH GmbH Precision Connectors – hereinafter referred to as “WEH”.

Type TW241
WEH®Connector for pressure and vacuum tests of straight tubes
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 12
5. STORAGE 13
5.1 Safety instructions for proper storage 13
5.2 Storage 14
6. REQUIRED TOOLS 14
7. INSTALLATION 16
7.1 Safety instructions for installation 16
7.2 Installing the media line for body size 1 to 3 17
7.3 Installing the media line for body size 4 to 7 17
7.4 Checking the connection for leak tightness 18
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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 19
8.1 Safety instructions for operation 19
8.2 Connection 20
8.3 Disconnection 21
9. INSPECTION | MAINTENANCE 22
9.1 Safety instructions for inspection and maintenance 22
9.2 Maintenance intervals 23
9.3 Overview of minimum intervals for inspection and maintenance 23
9.4 Maintenance 24
10. LUBRICATION 36
10.1 Safety instructions for lubrication 36
10.2 Lubrication 36
11. TROUBLESHOOTING 37
12. DISPOSAL 39
13. ACCESSORIES | SPARE PARTS 39
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1. INTRODUCTION
Dear Customer,
thank you for deciding to use our products.
The WEH®TW241 Connector has been developed for pressure and vacuum testing of
straight tubes.
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®TW241 Connector has been developed for pressure and vacuum testing
of straight tubes. The connector comes in many different sizes and forms.
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
on 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®TW241 Connector – Body size 1 to 3
Pos� Description
1 Base unit
2 Clamping lever
3 Bolt
4 Screw
5 Lever extension (optional)
7 Front seal (inside)
Definition of ports
B1 Media inlet
1
7
B1
2
3
4
TW241 with lever extension
5
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WEH®TW241 Connector – Body size 4 to 7
Pos� Description
1 Base unit
2 Clamping lever
6
Suspension attachment incl.
bore for chain safety device
(optional)
7 Front seal (inside)
Definition of ports
B1 Media inlet
TW241 with suspension attachment
6
1
7
B1
2
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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 - 24.1 mm, depending on the design
Max. allowable operat-
ing pressure PS Vacuum up to 70 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 Chloroprene
Actuation Manual actuation via clamping lever
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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 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.
ÎStore the WEH®Connector with the clamping lever released. The clamping lever
must not be actuated. The service life of the seals will be shortened if the seals are
left in the clamped position for a long time without a test piece.
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
-- Vice with plastic jaws X X
WEH®Hook wrench Ø34 - 36 mm
(suitable for the torque wrench) X
WEH®Joint-hook wrench Ø35 - 60 mm
(suitable for the torque wrench) X
-- Rolling fork insertion tool A/F2 - 41 X
-- Rolling fork wrench size 50 X
-- Hook wrench Ø34 - 36 mm X
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Part no� Description Installation Maintenance &
Lubrication
-- Joint-hook wrench Ø35 - 60 mm X
-- Brush X
E34-136114 WEH®Clamping jaws for Ø52 mm X
E34-136115 WEH®Clamping jaws for Ø57 mm X
E34-136116 WEH®Clamping jaws for Ø62 mm X
E34-136117 WEH®Clamping jaws for Ø67 mm X
W136538 WEH®O-ring picker set*X
E99-44923 WEH®Maintenance spray X
E99-40 WEH®Lubricant X
E99-74725 WEH®Lubricant X
E99-9 WEH®Degreasing spray X
E99-90160 WEH®Threadlocking adhesive 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 haz-
ardous applications or under hazardous conditions.
Please note: For body size 4 to 7, a suspension attachment (Pos. 6), which is / will be
attached to the media inlet ‘B1’, is available for this purpose.
ÎUSIT rings should be used to seal the ports.
ÎBefore installation, check if the counterparts are designed to withstand the assembly
data (see Chapter 7.2 Installing the media line for body size 1 to 3) that WEH deter-
mined 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.
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7�2 Installing the media line for body size 1 to 3
Please note: Subsequent mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
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 line (Figure 1).
For the tightening torque, please refer to the table below.
Ports Torque
1/8" female thread 10 Nm ± 2 Nm
1/4" female thread 30 Nm ± 2 Nm
3/4" female thread 60 Nm ± 2 Nm
ÎPlease note the connection size marked on your product.
- Other connection sizes are available on request.
7�3 Installing the media line for body size 4 to 7
Please note: Subsequent mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
ÎUnscrew the protection cap from the port.
ÎClamp the WEH®Connector in a vice with aluminium
clamping jaws to mount the media line.
Note: The WEH®Connector must not be damaged during
clamping.
ÎScrew the ‘B1’ media inlet pressure-tight to the port for the
media line (Figure 2).
For the tightening torque, please refer to the table above.
Figure 1
A/F(1)
B1
Figure 2
B1
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7�4 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.
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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.
ÎDo not actuate the WEH®Connector without a test piece. The seals can be damaged
without the test piece connected.
ÎOnce the connection has been made, always test the connection by tugging a little
on the WEH®Connector to make sure that 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.
ÎNote that the clamping lever (Pos. 2) is equipped with a short lever as standard. This
allows convenient connection to components that are difficult to access. Depending
on the application, the WEH®Connector can be equipped with a lever extension for
ease of use and when space is not limited. Please refer to Chapter 9.4.5 Assembly of
the lever extension (Pos. 5) for body size 1 to 3 on page 33.
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8�2 Connection
ÎMove the clamping lever (Pos. 2) to the straight starting position (Figure 3).
ÎGrip the connector by its base unit (Pos. 1) and plug it up
to the stop straight onto the test piece (Figure 4). 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 connector carefully and not with force
onto the test piece.
ÎActuate the clamping lever (Pos. 2) upwards or down-
wards (Figure 5). The connector tightens itself to the test
piece and creates a pressure-tight connection.
Attention: Make sure that the clamping jaws on the test
piece grip correctly, that the connector is seated properly
(it must not wobble) and that the pressure-tight connec-
tion has been made. Only then is the connector connected
correctly. Otherwise the connector may spring out of place
and medium may escape.
ÎPull lightly on the connector (red arrow Figure 6) 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 4
Figure 5
Figure 6
pull backwards
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