Weh CLICKMATE TW154 User manual

D-2007/10/00250-8-3 | Date: 08/2019
OPERATING INSTRUCTIONS
CLICKMATE™ TW154
for filling respiratory air cylinders 200 bar
for direct connection to the filling hose
WEH®- We Engineer Hightech

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 200 bar
Page 2
D-2007/10/00250-8-3
CONTENTS
PLEASE NOTE ��������������������������������� 3
1 GENERAL SAFETY INSTRUCTIONS ������������� 3
2 APPLICATION ��������������������������������� 4
3 INSTALLATION �������������������������������� 4
4 OPERATION ����������������������������������� 6
5 ACCESSORIES | SPARE PARTS ����������������� 8
6 STORAGE ������������������������������������� 8
7 MAINTENANCE�������������������������������� 8
8 REPLACEMENT OF FRONT SEAL �������������� 10
9 TROUBLE SHOOTING | CORRECTIVE ACTION��� 11
10 DIMENSIONS�������������������������������� 12

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 200 bar
Page 3
D-2007/10/00250-8-3
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 hose filling systems.
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 200 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.

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 200 bar
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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 200 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�11�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�11�3 Only use the type CLICKMATE™ TW154 200 bar for a pressure range up to max.
250 bar (PS) and a temperature range of +5 °C bis +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�11�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�10 WEH®Products may only be repaired or operated by the manufacturer or authorized
service personnel. If in doubt 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.
3 INSTALLATION
Pos� Description
1Operating loop
2Locking device
(200 bar black)
Definition ports
Media inlet
B1
1
2
B1

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 200 bar
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3�1 Safety instructions for installation
3�1�1 Check the cylinder ports and the CLICKMATE™ TW154 200 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 Installation must only be effected in depressurized condition.
3�1�5 Avoid lateral forces, e.g. caused by a restricted bending radius for the filling hose
or using short filling hoses. This could cause leakage.
3�1�6 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 CLICKMATE™ TW154 200 bar
3�2�1 Connect the filling hose pressure-tight to the media inlet 'B1' of the
CLICKMATE™ TW154 200 bar. Torque 20 Nm (M16x1.5 external thread).
3�2�2 Check the CLICKMATE™ TW154 200 bar for leak tightness and correct function
by actuating the CLICKMATE™ TW154 200 bar several times and check if the
clamping jaws open and close properly.
3�2�3 The CLICKMATE™ TW154 200 bar is now ready to operate.
M16x1.5
M16x1.5
M16x1.5
M16x1.5
A/F22 A/F17 A/F22
Quick Connector
CLICKMATE™ TW154 200 bar
(loop no. 1)
Quick Connector
CLICKMATE™ TW154 200 bar
(loop no. 72)
Swivel joint TD1
Adaptor
Filling hose
G5/8“
M16x1.5
A/F27
Adaptor 200 bar

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 200 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 200 bar only after complete pressure
venting. In case the operating loop (pos. 1) is lifted in pressurized condition, the
safety peg locks the operating loop (pos. 1) 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 200 bar to faultless cylinder valves.
4�1�5 The cylinders to be filled have to be fixed firmly when using quick connectors with
filling hoses. When using pallets, make sure that no accumulation of escaping air
may occur.
4�1�6 For easy handling, we recommend to use the WEH®Swivel joint TD1 to prevent
twisting of the hose when connecting.
NOTE: The CLICKMATE™ TW154 200 bar is equipped with a safety peg (figure 9,
page 9) that is actuated at a pressure between 15 and 20 bar, locking the operating loop
(pos. 1) and preventing disconnection under pressure. After completion of the filling
procedure and complete pressure venting, the safety peg retracts allowing the operating
loop (pos. 1) to be lifted easily into its initial position. The safety peg can be damaged if the
operating loop (pos. 1) 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 (pos. 2) and a
red marking at the front part of the connector (figure 1) indicating the proper connection of the
CLICKMATE™ TW154 200 bar.
4�2�1 Lift the operating loop (pos� 1) until it stops (figure 2)� Align the CLICKMATE™
TW154 200 bar in a straight horizontal line to the cylinder valve thus preventing
damage to the front seal by sharp edges of the valve. Place the CLICKMATE™
TW154 200 bar into the cylinder valve until it stops. Do not use force.
4�2�2 Lower the operating loop (pos� 1) until it stops (figure 3)� 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 cylinder thread, the valve is sealed and the pressure-tight connection is made
(figure 4).
4�2�3 Check the connection. Ensure that the operating loop (pos. 1) has travelled
through its full stroke to a point below the centre line of the CLICKMATE™ TW154
200 bar (figure 5) to enable the safety peg to protrude when pressure is applied.
The jaws must fully clamp into the thread.
4 OPERATION
Figure 5
Green ring
Red marking
Figure 1
Figure 2
Figure 3
Figure 4

Operating instructions Date: 08/2019
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
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�4 Open the filling valve (pressure present at cylinder valve). Please check that the
safety peg of the connector is protruded thus locking the sleeve and preventing
disconnection.
4�2�5 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 filling valve vent the filling hose.
4�3�3 After complete pressure venting, the connector can be disconnected.
Please note: 4.1.2.
Releasing the connection
4�3�4 Actuate the locking lever (pos. 2) and keep it pressed (figure 6).
4�3�5 Lift the operating loop (pos. 1) completely until it stops (figure 7).
4�3�6 Remove the CLICKMATE™ TW154 200 bar straight backwards from the cylinder
valve to avoid damage to the front seal!
Figure 6
Figure 7

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 200 bar
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5 ACCESSORIES | SPARE PARTS
Adaptor
Adaptor for connection to the filling hose resp. for connection of the filling hose with 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®Lubricant
*NOTE: The O-ring picker is manufactured from plastic and has to be considered as a consumable product!
6 STORAGE
Protect the connector against damage, dirt ingress, improper storage and excessive
temperature fluctuations.
Swivel joint TD1
The swivel joint TD1 prevents twisting of the filling hose and facilitates radial alignment of the
connector.
Part No� Description Pressure Connections
W6599 Swivel joint TD1 200 bar / 300 bar M16x1.5 external thread /
M16x1.5 internal thread
B200B-049-00 Seal set for TD1 - -
Part No� Description Connections
E68-32040 Hose length 1.5 m / Nominal bore DN 5 mm
(incl. TÜV approval) M16x1.5 internal thread
Other hose lengths on request
Filling hose
Spare parts
The following parts are available for product maintenance:
7 MAINTENANCE
Violation of WEH maintenance 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.
HINWEIS: If damages or limitations of the functionality are noted, measures according to the
table on page 11 must be taken. Damaged or leaking connectors must be sent to WEH.
7�1 Safety instructions for maintenance
7�1�1 Do not dismantle the CLICKMATE™ TW154 200 bar.
7�1�2 WEH®Products may only be repaired by the manufacturer or authorized service
personnel. If in doubt please contact us.
Part No� Description Pressure Connections
W50357 For connection CLICKMATE™
TW154 200 bar / filling hose 200 bar
M16x1.5 external thread with
inner cone / M16x1.5 internal
thread incl. O-ring
W32294 For connection filling hose /
filling rig 200 bar
M16x1.5 external thread with
inner cone / G5/8“ internal
thread DIN 477 No. 13

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 200 bar
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D-2007/10/00250-8-3
Figure 8
Fastening screw
Figure 9
Safety peg
Figure 10
Body set screw
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 CLICKMATE™ TW154 200 bar with soap solutions. Cleaning with
soap solutions causes a build-up that can hamper proper connector operation.
7�1�5 Avoid connector contact with any petroleum based chemicals that can cause
product contamination and damage.
7�2 Maintenance instructions
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 CLICKMATE™ TW154 200 bar once a week for wear of seals, damage
to the sleeve or the operating loop, missing or loosened fastening screws at the
operating loop (figure 8), leak tightness and proper function (free-moving, wear,
dirt accumulation,damage).
7�2�5 Daily check safety peg operation (figure 9). The safety peg must 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 CLICKMATE™ TW154
200 bar to WEH for change of the safety peg.
7�2�6 The main body set screw (figure 10) should be inspected periodically.
Torque 20 Nm.
7�2�7 Check the position of the handle at the hose (figure 11) regularly. The handle
must always be close to the screw connection to protect the hose from bending.
7�3 Regularly check the operating loop for sufficient lubrication
7�3�1 Apply WEH®Lubricant part no. E99-10 to the area marked with a red arrow
(figure 12) using an appropriate tool (small screwdriver).
7�3�2 Actuate the operating loop several times.
The CLICKMATE™ TW154 200 bar has to be maintained at yearly intervals, but at the latest
after 20,000 cycles or after 3 years by WEH�
Figure 11
Hose handle
Figure 12

Operating instructions Date: 08/2019
CLICKMATE™ TW154 - 200 bar
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8 REPLACEMENT OF FRONT SEAL
Figure 13
Front seal
Figure 14
Bevel
Note: Before installing, visually inspect the connector and check for correct type, body
material, clamping jaws, seal 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. The O-ring picker part no. E98-101969 is all that is needed. Insert the O-Ring
picker into the recess (figure 13), lift the front seal and remove it. The new front seal can
be inserted without using any tool.
NOTE: Please observe the correct installation direction! The bevelled side must face to
the connector (figure 14)!
8�2 Regularly check the swivel joint for wear of seals, dirt accumulation and free movement.
The swivel joint can be mounted and dismounted at the spanner flats (figure 15). Tigh-
ten the thread with max. 20 Nm. Don‘t overtighten the fitting by using higher torques as
fracturing can occur.
A/F22
A/F17
A/F22
B1
Figure 15

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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.
Lubricate safety peg.
Only lubricate oxygen connectors with grease
appropriated for oxygen!
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.
4
The socket head screw
securing the cam of the
operation loop is loose.
Loose screw Fittings are loose Change screw. Tighten the screw to 7 Nm.
5Faulty connection Visual inspection.
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 joint by using new WEH
®
original
joint. Do not use Loctite.
Safety peg leaking Dirt, wear of inner joints 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
Check the cylinder valve first 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: 08/2019
CLICKMATE™ TW154 - 200 bar
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10 DIMENSIONS
CLICKMATE™ TW154 with operating loop no� 72
approx. dimensions (mm)
Description Pressure
(PN)
Connection A
(internal thread)
Inlet B1
(external thread) L
CLICKMATE™ TW154
(black locking device) 200 bar G5/8“* M16x1.5 122
* acc. to DIN 477
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“* M16x1.5 122
* acc. to DIN 477
Ø 35
Ø 40
Ø 45
70
97
L1
102
B1
194
A
200 bar
B1
Ø 45
70
97
L1
Ø 35
Ø 40
214
96
A
200 bar
Ø 35 Ø 40 Ø 45
70
97
L1
102
B1
194
A
200 bar
B1
Ø 45
70
97
L1
Ø 35 Ø 40
214
96
A
200 bar
© All rights reserved, WEH GmbH 2019. 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