Weh CLICKMATE TW154 User manual

D-2007/10/00252-9-3 | Date: 09/2015
OPERATING INSTRUCTIONS
CLICKMATE™ TW154
for filling respiratory air cylinders 200 bar
for conversion of existing filling rigs
WEH®- We Engineer Hightech

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 2
D-2007/10/00252-9-3
CONTENTS
PLEASE NOTE ��������������������������������� 3
1 GENERAL SAFETY INSTRUCTIONS ������������� 3
2 APPLICATION ��������������������������������� 4
3 INSTALLATION �������������������������������� 5
4 OPERATION ����������������������������������� 8
5 ACCESSORIES | SPARE PARTS ���������������� 10
6 STORAGE ������������������������������������ 10
7 MAINTENANCE������������������������������� 11
8 REPLACEMENT OF FRONT SEAL �������������� 12
9 TROUBLE SHOOTING | CORRECTIVE ACTION��� 13
10 DIMENSIONS�������������������������������� 14

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 3
D-2007/10/00252-9-3
Dear Customer!
Thank you for deciding to use a WEH®Product.
The CLICKMATE™ TW154 200 bar has been specially designed for filling of BA cylinders and
direct connection to existing filling rigs that have balancers to equalize weight and height.
Each delivery must contain:
a) A delivery note
b) An original WEH test report (this does not apply to spare parts)
c) WEH operating instructions
For missing documents please contact WEH.
Our ‘General Terms and Conditions’ apply.
Read these operating instructions carefully and follow them whilst using the WEH®Product�
The statements in these instructions correspond to the state of knowledge at the time of
printing� Failure to observe these instructions may result in a loss of warranty� Any variations
to these instructions have to be confirmed by the WEH QA management in writing�
Violation of WEH operating instructions will result in a loss of warranty and in addition the WEH
GmbH will accept no liability for consequential damage caused to persons or property�
PLEASE NOTE
1 GENERAL SAFETY INSTRUCTIONS
For your own safety, please observe the following instructions�
1�1 Only to be operated by authorized service personnel.
1�2 Service personnel as defined by these instructions are persons able to evaluate the work
entrusted to them and to recognize possible dangers according to their knowledge and
experience and their knowledge of the standards applicable.
1�3 Please conform to any relevant legal directives, such as for instance any national
legislation on safety and health at work. Observe the relevant approval standards and
directives.
1�4 These operating instructions should be provided to each person responsible for
installation, operation and maintenance of the product.
1�5 If instructions are not completely understood by operators, contact WEH before
attempting use of the product.
1�6 Where dangerous operating conditions exist, appropriate safety measures must be taken.
1�7 In case of damage and queries concerning the proper functioning of the product, do not
use the product until clarification has been sought. The product should only be
dismantled by WEH.
1�8 The WEH GmbH is not responsible for any damage resulting from factors outside their
control.
1�9 Transportation and storage facilities suitable for protection of the product must be used
at all times.
1�10 WEH®Products may only be repaired by the manufacturer. Please contact us.
1�11 Observe the torques indicated in these operating instructions. Tightening with a higher
torque can result in fracture damage when the system is pressurized.

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 4
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2 APPLICATION
The application is defined in the catalogue and in the accompanying product documentation.
Please check that the product marking, delivery note and test report comply with the
application.
If you are not certain about correct installation please contact us before using the equipment.
2�1 Safety instructions for application
2�1�1 Ensure the proper use: The product may be used only if the specified operating
pressure and temperature are not exceeded, and the design criteria and media
defined in the order are complied with. Please check that the product documen-
tation supplied corresponds to the product marking.
2�1�2 Suitability for application: When selecting a component, the total system design
must be considered to ensure safe, trouble-free performance. The correct
selection of a component, material, temperature, pressure range as well as
proper installation, operation and maintenance are the responsibility of the
customer.
2�1�3 Only use the product for a pressure range up to max. 250 bar (PS) and a tempera-
ture range of +5 °C up to +70 °C. Please observe the
pressure limits specified in the relevant cylinder valve standard. They could be
lower than the max. operating pressure of the WEH®Connector.
2�1�4 Safety restraints, chains or guards are recommended for additional operator
safety when used under hazardous conditions.
2�1�5 This WEH®Product is generally and exclusively classified as pressure accessory
for piping in accordance with Article 2 (5) of the Pressure Equipment Directive
2014/68/EU. This WEH®Product may not be used (i) as safety accessory or (ii) for
vessels as defined by the Pressure Equipment Directive 2014/68/EU. Therefore, the
application of this WEH®Product must comply with the classification as pressure
accessory for piping. The assessment with regard to a different classification can,
however, be made on request.

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 5
D-2007/10/00252-9-3
3�1 Safety instructions for installation
3�1�1 Check the product for external damage.
3�1�2 Please check that the product documentation and product marking
comply with the application.
3�1�3 Check the product for any damage in transit.
3�1�4 Ensure that the whole system is unpressurized before starting conversion of the
filling rig.
3�1�5 Please note that a minimum space of 180 mm from connector centre to connec-
tor centre has to be observed at the filling rig!
3�1�6 The assembly data indicated (tightening torques, assembly turns etc.) are max.
values and only valid for components delivered by WEH. The customer is
responsible to check if his components withstand these max. values determined
by WEH.
3�2 Installation of the CLICKMATE™ TW154 200 bar at the filling rig (Adaptor W30225)
3�2�1 Loosen the existing screw connection and remove it.
3�2�2 Pre-assemble the adaptor (see figure above). Place the locking nut (Pos. 2) onto
the adaptor (Pos. 4). The O-ring seal (Pos. 5) must be properly seated in the
recess of the adaptor (Pos. 4).
3�2�3 Fully screw the adaptor (Pos. 4) into the filling rig. Max. torque 20 Nm.
3�2�4 Screw together the CLICKMATE™ TW154 200 bar and the adaptor (Pos. 4):
Slightly grease the O-ring (Pos. 3) with Part No. E99-10 and place it into the
plane recess of the adaptor (Pos. 4). Screw the locking nut (Pos. 2) onto
port ‘B1’ of the CLICKMATE™ TW154 200 bar. The loop of the
CLICKMATE™ TW154 200 bar must be aligned horizontally. Tighten the locking
nut (Pos. 2) whilst holding the CLICKMATE™ TW54 200 bar. Torque: 20 Nm.
3 INSTALLATION
Pos� Description
1CLICKMATE™ TW154
200 bar
2Locking nut
3O-ring
4Adaptor
5O-ring
Definition ports
Media inlet
B1 1
2
4
3
5
B1

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
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3�3 Installation of the CLICKMATE™ TW154 200 bar at the filling rig (Adaptor W30124)
3�3�1 Loosen the existing screw connection and remove it.
3�3�2 Pre-assemble the adaptor (see figure above). Place the locking nut (Pos. 2) and
the counter hexagonal nut (Pos. 6) onto the adaptor (Pos. 4). Slightly grease the
O-ring (Pos. 5) with Part No. E99-10 and place it into the rearward plane recess
of the adaptor (Pos. 4).
3�3�3 Fully screw the adaptor (Pos. 4) into the filling rig. Max. torque 20 Nm.
Tighten the counter hexagonal nut (Pos. 6).
3�3�4 Screw together the CLICKMATE™ TW154 200 bar and the adaptor (Pos. 4):
Slightly grease the O-ring (Pos. 3) with Part No. E99-10 and place it into the plane
recess of the adaptor (Pos. 4). Screw the locking nut (Pos. 2) onto port ‘B1’ of the
CLICKMATE™ TW154 200 bar. The loop of the CLICKMATE™ TW154 200 bar must
be aligned horizontally. Tighten the locking nut (Pos. 2) whilst holding the
CLICKMATE™ TW154 200 bar. Torque: 20 Nm.
Pos� Description
1CLICKMATE™ TW154
200 bar
2Locking nut
3O-ring
4Adaptor
5O-ring
6Counter hexagonal nut
Definition ports
Media inlet
B1 1
2
4
3
5
6
B1

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
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3�4 Installation of the CLICKMATE™ TW154 200 bar at the filling rig (Adaptor W35631)
3�4�1 Loosen the existing screw connection and remove it.
3�4�2 Pre-assemble the adaptor (see figure above). Place the locking nut (Pos. 2) onto the
adaptor (Pos. 4). Place the plane sealing of the customer onto the adaptor (Pos. 4)
(WEH recommends to use an usit ring).
3�4�3 Fully screw the adaptor (Pos. 4) into the filling rig. Max. torque 20 Nm
(torque only valid for use with usit ring).
3�4�4 Screw together the CLICKMATE™ TW154 200 bar and the adaptor (Pos. 4):
Slightly grease the O-ring (Pos. 3) with Part No. E99-10 and place it into the plane
recess of the adaptor (Pos. 4). Screw the locking nut (Pos. 2) onto port ‘B1’ of the
CLICKMATE™ TW154 200 bar. The loop of the CLICKMATE™ TW154 200 bar must
be aligned horizontally. Tighten the locking nut (Pos. 2) whilst holding the CLICK-
MATE™ TW154 200 bar. Torque: 20 Nm.
3�5 Installation Weight and height balancing system TZ100
3�5�1 Place the breathing air cylinder onto the cylinder holder of the weight and height
balancing system. Connect the cylinder valve to the CLICKMATE™ TW154 200 bar
and align the cylinder to a vertical position in all directions (figure 1).
3�5�2 Mark out the fixing holes with a marker pen. Drill the holes. Fit the dowels.
Screw in the screws with washers by hand and tighten with a spanner
(figure 2).
Pos� Description
1CLICKMATE™ TW154
200 bar
2Locking nut
3O-ring
4Adaptor
Definition ports
Media inlet
B1
1
2
4
3
B1
Figure 1
Figure 2

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 8
D-2007/10/00252-9-3
4�1 Safety instructions for operation
4�1�1 Observe the right order when connecting and disconnecting the
WEH®Connector.
4�1�2 Disconnect the WEH®Connector only after complete pressure venting. In case
the operating loop is lifted in pressurized condition, the safety peg locks the
operating loop and prevents disconnection under pressure. If force is used to
actuate the loop with the safety peg extended, the safety peg could be damaged.
4�1�3 Do not use excessive force when connecting.
4�1�4 Do only connect the WEH®Connector to faultless cylinder valves.
4�1�5 Please note: Only use cylinders of a size suitable for the TZ100 weight and height
balancing system used. When positioning the gas cylinder onto the cylinder
holder of the TZ100, the cylinder valve has to be above the connection port of the
CLICKMATE™ TW154 200 bar. If this is not the case, the cylinder size is not
appropriate for the weight and height balancing system size.
NOTE: The CLICKMATE™ TW154 200 bar is equipped with a safety peg (figure 11,
page 12) that is actuated at a pressure between 15 and 20 bar, locking the operating loop
and preventing disconnection under pressure. After completion of the filling procedure
and complete pressure venting, the safety peg retracts allowing the operating loop to be
lifted easily into its initial position. The safety peg can be damaged if the operating loop is
forcibly actuated before the system has been completely vented and the safety peg is still
visible.
4�2 Connection
The CLICKMATE™ TW154 200 bar has a green control ring at the locking device and a red
marking at the front part of the connector (figure 3) indicating the proper connection of the
CLICKMATE™ TW154 200 bar.
4�2�1 Place the cylinder onto the cylinder holder of the weight and height balancing sys-
tem. Press the cylinder down until the cylinder valve is opposite the CLICKMATE™
TW154 200 bar (figure 4) connection port.
4�2�2 Lift the operating loop until it stops� Align the cylinder valve with the connector
thus preventing damage to the front seal by sharp edges of the valve. Place the
cylinder valve loose onto the CLICKMATE™ TW154 200 bar until it stops. Do not
use force.
4�2�3 Lower the operating loop until it stops (figure 5)� The operator must be able to
lower the operating loop easily and without using force. The loop must lock into
place with an audible ‚click‘. The clamping jaws are locked, clamp into the cylin-
der thread, the valve is sealed and the pressure-tight connection is made.
4�2�4 Check the connection. Ensure that the operating loop has travelled through its
full stroke to a point below the centre line of the CLICKMATE™ TW154 200 bar
(figure 6) to enable the safety peg to protrude when pressure is applied. The jaws
must fully clamp into the thread.
4 OPERATION
Green ring
Red marking
Figure 3
Figure 4
Figure 5
Figure 6

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
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WRONG RIGHT
Green ring
not visible
Grüner Ring
sichtbar
Green ring
visible
Red marking
visible
Red marking
not visible
Figure 7
The CLICKMATE™ TW154 200 bar is only connected properly if the green ring (visual
inspection, see pictures above) is completely visible and the red marking at the front part
is not visible. If not, start connecting procedure again.
NOTE: GREEN RING VISIBLE + RED MARKING NOT VISIBLE
PROPER CONNECTION
4�2�5 Open the valve at the filling rig (pressure present at cylinder valve, figure 7).
Please check that the safety peg of the connector is protruded thus locking the
sleeve and preventing disconnection.
4�2�6 Now open the cylinder valve the cylinder is being filled.
4�3 Disconnection
After filling
4�3�1 Close the cylinder valve.
4�3�2 Close the valve at the filling rig vent the filling hose.
4�3�3 After complete pressure venting, the CLICKMATE™ TW154 200 bar can be
disconnected. Please note: 4.1.2.

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 10
D-2007/10/00252-9-3
Figure 8
Figure 9
5 ACCESSORIES | SPARE PARTS
Adaptor incl� locking nut
Adaptors with various threads are available for connection to the filling rig.
Part No� Pressure Connection
W30225 200 bar / 300 bar M16x1.5 external thread with O-ring for sealing on collar Ø 12.9 mm
W30124 200 bar / 300 bar M16x1.5 external thread with O-ring for plane sealing
W35631 200 bar / 300 bar G1/4“ external thread plane sealing
Weight and height balancing system TZ100
For safe positioning of the cylinders below the filling rig.
Part No� Description
E51-308S508 Front seal
W136538 O-ring picker set (consisting of 3 O-ring pickers, Part No. E98-101969)*
E99-10 WEH®High performance grease
*NOTE: The O-ring picker is manufactured from plastic and has to be considered as a consumable
product!
Releasing the connection
4�3�4 Actuate the locking device and keep it pressed (figure 8).
4�3�5 Lift the operating loop completely until it stops (figure 9).
4�3�6 Disconnect the cylinder slightly push the cylinder down pull the cylinder valve
rearwards to remove it from the CLICKMATE™ TW154 200 bar.
Attention: Remove the connector straight backwards to avoid damage to the
front seal.
Spare parts
The following parts are available for product maintenance:
Part No� Description Filling height
C1-66042 TZ100 System 1 825 - 870 mm
C1-66237 TZ100 System 2 840 - 910 mm
C1-66238 TZ100 System 3 880 - 980 mm
C1-66239 TZ100 System 4 955 - 1055 mm

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 11
D-2007/10/00252-9-3
7 MAINTENANCE
Violation of WEH maintenance instructions specified in this document will result in a loss of
warranty and in addition the WEH GmbH will accept no liability for consequential damage caused
to persons or property.
NOTE: If faults are noted during inspection, the guidelines in the table on page 14 must be
followed. Damaged or leaking connectors must be sent to WEH.
7�1 Safety instructions for maintenance
7�1�1 Do not dismantle the product.
7�1�2 WEH®Products may only be repaired by the manufacturer. Please contact us.
7�1�3 Only use original WEH®Spare parts. These fit the application correctly and are
subject to strict quality control.
7�1�4 Do not clean the WEH® Connector with soap solutions. Soap solutions may form
a layer that can hamper proper connector operation. Clean the connector by
blowing it off with compressed air and remove adhering dirt using a damp and
soft cloth.
Do not use solvents, only clear water.“
7�1�5 Avoid connector contact with any mineral oil-based chemicals that can cause
product contamination and damage.
7�2 Maintenance instructions
The WEH®Connector has to be sent to the manufacturer for inspection at regular
intervals� At the latest, however, after 20,000 cycles or after 3 years, starting from the
date of shipment (WEH invoice date / WEH goods issue date)�
7�2�1 Daily check the surface of the front seal. Replace the front seal if tears, cracks
or damage are visible. The front seal has to be replaced at least every 500 cycles.
Should this interval be too long, shorter intervals must be determined.
7�2�2 Even with proper selection and installation, product life may be significantly
reduced without a continuing maintenance program. Frequency of maintenance
should be determined by the demands of the application and risk potential.
7�2�3 Periodically inspect the product for proper operation. Immediate withdrawal for
repair or replacement of the product is required if positive gripping or sealing
function and/or proper performance is not being achieved.
7�2�4 Check the product once a week for wear of seals, damage to the sleeve or the ope-
rating loop, missing or loosened fastening screws at the operating loop (figure 10),
leak tightness and proper function (free-moving, wear, dirt accumulation,damage).
7�2�5 Daily check safety peg operation (figure 11). The safety peg must
6 STORAGE
6�1 Protect the product against damage, dirt ingress, improper storage and excessive
temperature fluctuations.
6�2 Store the product, the accessories and spare parts in the original packaging until use.

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 12
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Figure 13
actuate between a pressure of 15 and 20 bar and retract when the system is
vented. If the safety peg does not function properly or is deformed, return the
WEH®Connector to WEH for change of the safety peg.
7�2�6 Check the tightening torque of the body set screw (figure 12) at each seal
replacement. Torque 20 Nm.
7�3 Regularly check the operating loop for sufficient lubrication
We recommend a lubrication interval of 4 - 6 weeks. Depending on the conditions of use,
however, the interval may be shorter. It lies in the responsibility of the customer to specify
a lubrication interval according to the individual operational requirements.
7�3�1 Apply WEH®Lubricant Part No. E99-10 onto the area marked with a red arrow
(figure 13) using an appropriate tool (small screwdriver).
7�3�2 Actuate the operating loop several times.
Figure 10
Fastening screw
Figure 11
Safety peg
Figure 12
Body set screw

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 13
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8 REPLACEMENT OF FRONT SEAL
Figure 14
Front seal
Figure 15
Bevel
Note: Before installing, visually inspect the connector and check for correct type, body
material, clamping jaws, sealing material and part number�
8�1 Replacement of the front seal
There is no need to dismantle the CLICKMATE™ TW154 200 bar in order to replace the
front seal. Do only use the O-ring picker Part No. E98-101969 for replacement. Insert the
O-ring picker into the recess (figure 14), lift the front seal and remove it. The new front
seal can be inserted without using any tool.
Please note: 7�2�6�
NOTE: Please observe the correct installation direction! The bevelled side must face to
the connector (figure 15)!

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 14
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9 TROUBLE SHOOTING | CORRECTIVE ACTION
No� Fault Can be recognised by Possible cause Remedial measures
1
Gas leak when starting fil-
ling procedure, decreasing
with increasing pressure.
Feel for leak when filling
starts, blow-off sound. Improper connection Stop filling, repeat connecting procedure.
Increasing gas leak when
pressure increases. Blow-off sound
Faulty front seal Stop filling. Replace front seal
Valve thread damaged
Decide whether filling
should be stopped or
continued.
Exchange valve.
2
Safety peg does not protru-
de during pressurization
Feeling at outlet or visual
inspection
Safety peg distorted. Stop filling. Send CLICKMATE™ to WEH for change of
the safety peg.
Insufficient
lubrication / dirty
Replace connector before proceeding with filling,
respectively perform maintenance.
Low filling pressure Filling pressure must be between 15 and 20 bar for
peg actuation.
Safety peg does not move
back into the body.
Visual inspection.
Operating loop cannot
be moved to opening
position.
System not depressurized
sufficiently.
Check if cylinder valves are closed.
Proceed to depressurize.
Safety peg seized because
of insufficient lubrication. Return CLICKMATE™ to WEH for maintenance.
Safety peg seized,
distorted
Push safety peg into connector by hand or with a tool.
Return CLICKMATE™ to WEH for change of the safety
peg.
3
Deformation or distortion of sleeve or operating loop,
locking device, connecting pieces thus difficult to
operate, leaking of body or fittings.
Improper handling Replace CLICKMATE™ immediately and return to WEH
for maintenance.
4Operating loop is loose. Operating loop moves
noticeably at the cam
The socket head screw
securing the cam of the
operating loop is loose.
Tighten screw to 7Nm. If necessary, replace screw.
5Faulty connection Visual control.
Green ring not visible.
Operating loop is not
lowered completely. Lower the operating loop completely downwards.
Clamping jaws do not
clamp into the thread of the
cylinder valve.
Connect again.
6
Connecting thread leaking
Blow-off sound
Fittings are loose
Tighten the fittings to max. 20 Nm. Each fitting has
to be held with a second wrench. If necessary open
fittings and replace seal by new, original WEH
®
seal.
Do not use Loctite!
Safety peg leaking Dirt, wear of inner seals Return CLICKMATE™ to WEH for change of the safety
peg.
7Jaws of collets have not
expanded properly.
Connector is too loose,
can be moved within the
valve thread.
Wear
First check the cylinder valve with a thread gauge. If
thread is ok - replace CLICKMATE™; if thread is faulty
replace cylinder valve.
8Less than 4 threads are
engaged.
Threads showing out of
the end of the valve.
Wear of connector cams of
the operating loop Replace connector.
Wrong cylinder valve Check cylinder valve.
9
Faulty connecting thread at
cylinder valve, obviously
loose.
Connector is loose despite
proper connection.
Wear of connecting thread
of cylinder valve.
Separate pressure gas cylinder for replacement of
valve.
If problem persists after replacement of cylinder valve,
replace connector!
In case of problems contact manufacturer or distributor.

Operating instructions Date: 09/2015
CLICKMATE™ TW154 - 200 bar
Page 15
D-2007/10/00252-9-3
10 DIMENSIONS
CLICKMATE™ TW154 with operating loop no� 72
Ø 35
Ø 40
B1
Ø 45
70
102
L1
102
198
A
200 bar
approx. dimensions (mm)
Description Pressure
(PN)
Connection A
(internal thread)
Inlet B1
(external thread) L
CLICKMATE™ TW154
(black locking device) 200 bar G5/8“* NS 1“-14 126
Quick connector CLICKMATE™ TW154 with operating loop no� 1
approx. dimensions (mm)
Description Pressure
(PN)
Connection A
(internal thread)
Inlet B1
(external thread) L
CLICKMATE™ TW154
(black locking device) 200 bar G5/8“* NS 1“-14 126
102
L1
B1
Ø 45
70
Ø 35 Ø 40
218
96
200 bar
A
Ø 35 Ø 40
B1
Ø 45
70
102
L1
102
198
A
200 bar
102
L1
B1
Ø 45
70
Ø 35 Ø 40
218
96
200 bar
A
* acc. to DIN 477
* acc. to DIN 477
© All rights reserved, WEH GmbH 2013. Any unauthorized use is strictly forbidden. Subject to alteration. No liability will be assumed for any content. Herewith previous versions are no longer valid.
For queries and further information, please do not hesitate to contact us.
»Contacting
Manufacturer:
WEH GmbH Precision Connectors
Josef-Henle-Straße 1
89257 Illertissen / Germany
Phone: [phone]
Fax: [phone]
eMail: [e-mail]
www.weh.com