Weh CLICKMATE TW154 User manual

D-2007/10/00253-9-3 | Date: 08/2019
OPERATING INSTRUCTIONS
CLICKMATE™ TW154
for filling respiratory air cylinders 300 bar
for conversion of existing filling rigs
WEH®- We Engineer Hightech

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 300 bar
Page 2
D-2007/10/00253-9-3
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: 08/2019
CLICKMATE™ TW154 - 300 bar
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D-2007/10/00253-9-3
Dear Customer!
Thank you for deciding to use a WEH®Product.
The CLICKMATE™ TW154 300 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 CLICKMATE™ TW154 300 bar.
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, avoid
use until clarification has been sought. The product should only be dismantled by WEH or
specially trained service personnel.
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 or operated by the manufacturer or authorized
service personnel. If in doubt please contact us.

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 300 bar
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D-2007/10/00253-9-3
2 APPLICATION
The application is defined in the catalogue and in the product documentation attached. 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 CLICKMATE™ TW154 300 bar 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 documentation 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 selec-
tion 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 type CLICKMATE™ TW154 300 bar for a pressure range up to max.
375 bar (PS) and a temperature range of +5 °C up to +70 °C. Please observe the
pressure limits specified in the relevant cylinder valve standard. This could be
lower than the max. operating pressure of the WEH®Connector.
2�1�4 Safety chains, ropes 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.
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: 08/2019
CLICKMATE™ TW154 - 300 bar
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3�1 Safety instructions for installation
3�1�1 Check the cylinder ports and the CLICKMATE™ TW154 300 bar for damage.
3�1�2 Please check that product documentation and product marking of the connector
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 The torques given are max. values, only valid for components delivered by WEH.
The customer is responsible to check if his components withstand the torques
determined by WEH as max. values.
3�2 Installation of the CLICKMATE™ TW154 300 bar at the filling rig (Adaptor W30225)
3�2�1 Loosen the existing screw filling 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 fit properly 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 Tighten CLICKMATE™ TW154 300 bar and adaptor (pos. 4): Greese the O-ring
(pos. 3) slightly with part no. E99-10 and place it into the plain recess of the adap-
tor (pos. 4). Screw the locking nut (pos. 2) onto inlet ‘B1’ of the CLICKMATE™.
The loop of the CLICKMATE™ must be aligned horizontally.
Tighten the locking nut (pos. 2) whilst holding it against the CLICKMATE™.
Max. torque 20 Nm.
3 INSTALLATION
Pos� Description
1CLICKMATE™ TW154
300 bar
2Locking nut
3O-ring
4Adaptor
5O-ring
Definition ports
Media inlet
B1
1
2
4
3
5
B1

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 300 bar
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3�3 Installation of the CLICKMATE™ TW154 300 bar at the filling rig (Adaptor W30124)
3�3�1 Loosen the existing screw filling 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). Grease the O-ring
(pos. 5) slightly with part no. E99-10 and place it into the rearward plain 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 Tighten CLICKMATE™ TW154 300 bar and adaptor (pos. 4). Grease the O-ring
(pos. 3) slightly with part no. E99-10 and place it into the plain recess of the adap-
tor (pos. 4). Screw the locking nut (pos. 2) onto inlet ‘B1’ of the CLICKMATE™.
The loop of the CLICKMATE™ must be aligned horizontally.
Tighten the locking nut (pos. 2) whilst holding it against the CLICKMATE™.
Max. torque 20 Nm.
Pos� Description
1CLICKMATE™ TW154
300 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: 08/2019
CLICKMATE™ TW154 - 300 bar
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3�4 Installation of the CLICKMATE™ TW154 300 bar at the filling rig (Adaptor W35631)
3�4�1 Loosen the existing screw filling 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 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 Tighten CLICKMATE™ TW154 300 bar and adaptor (pos. 4). Grease the O-ring
(pos. 3) slightly with part no. E99-10 and place it into the plain recess of the adap-
tor (pos. 4). Screw the locking nut (pos. 2) onto inlet ‘B1’ of the CLICKMATE™ .
The loop of the CLICKMATE™ must be aligned horizontally.
Tighten the locking nut (pos. 2) whilst holding it against the CLICKMATE™ .
Max. torque 20 Nm.
3�5 Installation Weight and height balancing system
3�5�1 Place the breathing air cylinder onto the cylinder holder of the weight and height
balancing system. Connect the CLICKMATE™ TW154 300 bar to the cylinder valve
and align it to a vertical position in all directions (see figure 1).
3�5�2 Mark out the fixing holes with a marker pen. Drill the holes. Fit the dowels.
Screw in the screws and washers by hand and tighten with a spanner
(see figure 2).
Pos� Description
1CLICKMATE™ TW154
300 bar
2Locking nut
3O-ring
4Adaptor
Definition ports
Media inlet
B1
1
2
4
3
B1
Figure 1
Figure 2

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 300 bar
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4�1 Safety instructions for connection and disconnection
4�1�1 Observe the right order when connecting and disconnecting.
4�1�2 Disconnect the CLICKMATE™ TW154 300 bar 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 CLICKMATE™ TW154 300 bar to faultless cylinder valves.
NOTE: The CLICKMATE™ TW154 300 bar is equipped with a safety peg (figure 11,
page 11) 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 300 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 300 bar.
4�2�1 Place the cylinder onto the holder of the balancing system and ensure that the
cylinder valve is aligned with the CLICKMATE™ TW154 300bar. Press the cylinder
down until the cylinder valve is opposite the CLICKMATE™ TW154 300 bar.
4�2�2 Lift the operating loop until it stops (figure 4)� 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 300 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 300 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: 08/2019
CLICKMATE™ TW154 - 300 bar
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The CLICKMATE™ TW154 300 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 300 bar can be
disconnected. Please note: 4.1.2.
WRONG RIGHT
Green ring
not visible
Grüner Ring
sichtbar
Green ring
visible
Red marking
visible
Red marking
not visible
Figure 7

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5 ACCESSORIES | SPARE PARTS
Adaptor incl� locking nut
Adaptors including locking nut with various threads for installation to the filling rig are available
for the CLICKMATE™ TW154 300 bar.
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.
Spare parts
The following parts are available for product maintenance:
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 and pull the cylinder
valve rearwards to remove it from the CLICKMATE™ TW154 300 bar.
Attention: Remove the cylinder straight backwards to avoid damage to the front
seal.
6 STORAGE
Protect the product against damage, dirt ingress, improper storage and excessive
temperature fluctuations.
Figure 8
Figure 9