Weh TK16 H2 User manual

WEH®- We Engineer Hightech
Type TK16 H2 | C1-171921
Operating instructions ⋅Betriebsanleitung | WEH USA
WEH®Fueling nozzle for refueling the fueling stations
WEH®Füllkupplung zur Betankung von Tankstellen

Die deutsche Version ist das Original.
Hersteller: WEH GmbH Gas Technology - im Nachfolgenden „WEH“ genannt.
LANGUAGES
TYPE TK16 H2 | C1-171921 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
WEH®Fueling nozzle for refueling the fueling stations
TYP TK16 H2 | C1-171921 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
WEH®Füllkupplung zur Betankung von Tankstellen
AE
DE
The German version is the original.
Manufacturer: WEH GmbH Gas Technology - hereafter referred to as 'WEH'.

Type TK16 H2 | C1-171921
WEH®Fueling nozzle for refueling the fueling stations
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 8
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 15
7. INSTALLATION 16
7.1 Safety instructions for installation 16
7.2 Installing the filling and venting hose 17
7.3 Checking the connection for leak tightness 17
7.4 Fitting the protective sleeve (Pos. 5) 17
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The German version is the original.
Manufacturer: WEH GmbH Gas Technology - hereafter referred to as 'WEH'.
8. OPERATION 18
8.1 Safety instructions for operation 18
8.2 Connection 18
8.3 Disconnection 19
9. INSPECTION | MAINTENANCE 20
9.1 Safety instructions for inspection and maintenance 20
9.2 Maintenance intervals 21
9.3 Overview of minimum intervals for inspection and maintenance 22
9.4 Maintenance 23
10. LUBRICATION 28
10.1 Safety instructions for lubrication 28
10.2 Lubrication 28
11. CHECKING THE LEAK RATE 29
11.1 Measuring the leak rate using a concentration meter 29
11.2 Safety instructions for connecting the service receptacle 30
11.3 Checking the leak rate 30
12. TROUBLESHOOTING 32
13. DISPOSAL 34
14. ACCESSORIES | SPARE PARTS 34
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1. INTRODUCTION
Dear Customer,
Thank you for deciding to use our products.
The WEH®TK16 H2| C1-171921 Fueling nozzle is designed exclusively for installation
on H2 trailers. This is used to fill the tanks of fueling stations equipped with a
TN1 H35 HF | C1-172279.
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
instructions 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.
ÎRead 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.
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.
- Proper transport and storage of the WEH®Product is assumed.
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.
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2. INTENDED USE
- The WEH®TK16 H2| C1-171921 Fueling nozzle is designed exclusively for installa-
tion on H2 trailers. This is used to fill the tanks of fueling stations equipped with a
TN1 H35 HF | C1-172279.
Attention: The WEH®Fueling nozzle must only be connected to the
TN1 H35 HF | C1-172279, as only this TN1 is designed for the high operating
pressure.
Never refuel vehicles with this fueling nozzle.
Refuel only the designated storage tanks of the fueling stations.
- The WEH®Product is not suitable to be operated with pre-cooled hydrogen. The
specified lower temperature limit refers to the minimum ambient temperature for
this product.
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®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.
Note: This fueling nozzle may only be operated by trained personnel. The fueling
nozzle may only be switched if it is connected to a corresponding receptacle which
is designed for this pressure or this application.
The fueling nozzle must not be used for refueling common hydrogen vehicles.
This is a special application for refueling the fueling stations.
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3. PRODUCT OVERVIEW / PRODUCT DESCRIPTION
Product overview - WEH®TK16 H2Fueling nozzle
Overview of Pressure Stage/Coding
Type Pressure range Part no� Compatible with
TK16 H242 MPa C1-171921 TN1 H35 HF
C1-172279
Due to the high operating pressure PS of 52 MPa, the TK16 H2| C1-171921 may only be
connected to the TN1 H35 HF | C1-172279 listed here.
Any other combination is not permissible and represents a safety risk.
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Product description
TK16 H2
Pos� Description
1Guide bush with
impact protection
2 Cover disc
3 Actuation lever
4 Countersunk screw (3x)
5 Protective sleeve
6 Swivel joint 360°
Definition of ports
B1 Media inlet
C2 Gas recirculation
4
6
1
23
5
B1
C2
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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.
TK16 H2
Characteristics Basic version
Nominal bore (DN) 8 mm
Pressure range PN = 41.6 MPa | PS = 52 MPa
Temperature range -40 °C to +85 °C
Parts materials Wear-resistant stainless steel, corrosion-resistant surfaces
Sealing material Hydrogen-resistant
Nozzle type Type A according to SAE J2600:2002, section 5.2
Design Thermally insulating plastic casing and gas recirculation
Weight Approx. 2.95 kg
Conformities /
Tests /
Approvals
--
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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 allowable storage time is valid from the date of delivery (invoice/goods
issue date from WEH or the distributor) on the label of the packaging. 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.
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6. REQUIRED TOOLS
Part No� Description Installation Checking the
leak rate
Mainte-
nance &
Lubrication
C1-148079 WEH®TNS1 H2Service
receptacle X X
WKZ-148012 WEH®Assembly tool X X
-- Open-ended spanner A/F16 X X
-- Open-ended spanner A/F19 X X
-- Calibrated torque wrench
(suitable for corresponding torque) X X
-- Open-ended spanner A/F16
(suitable for the torque wrench) X X
-- Open-ended spanner A/F19
(suitable for the torque wrench) X X
-- Hex bit A/F2.5
(suitable for the torque wrench) X X
-- Hexagonal
screwdriver A/F2.5 X X
-- Slotted screwdriver X
-- Open-ended spanner A/F14 X
-- Open-ended spanner A/F14
(suitable for the torque wrench) X
-- Vice with plastic jaws X
E99-90160 WEH®Threadlocking adhesive X
E99-35 WEH®Adhesive X
E99-9 WEH®Degreasing spray X
E99-44923 WEH®Maintenance spray X
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7. INSTALLATION
Please note: Subsequent mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
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 are designed to protect the product and
the 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 de-
pressurized condition.
ÎBefore installation, check if the counterparts are designed to withstand the assembly
data (see Chapter 7. Installation) that WEH determined for this WEH®Product.
Note: The assembly data (torques, assembly turns etc.) are values which apply exclu-
sively to the components delivered by WEH.
ÎBefore commissioning, make sure that the used hoses and the breakaway coupling
are also suitable for the application (e.g. filling with cryogenic medium).
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7�2 Installing the filling and venting hose
ÎUnscrew the three countersunk screws (Pos. 4) for the
protective sleeve (Pos. 5) using an Allen key A/F2.5.
Remove the protective sleeve and pull it over the filling and
venting hose that has been laid out ready.
ÎUnscrew the protection caps from the connection ports.
ÎWhen mounting the filling and venting hose, hold an
open-ended spanner against the spanner flat A/F(1) and
A/F(2) (Figure 1).
ÎScrew the media inlet ‘B1’ pressure-tight onto the connection port of the filling hose
(Figure 1).
Please see the table below for the tightening torque.
ÎScrew the gas recirculation ‘C2’ pressure tight onto the connection port of the vent-
ing hose (Figure 1).
Please see the table below for the tightening torque.
Ports Torque
UNF 7/16“-20*male thread 20 Nm +10%
UNF 9/16“-18*male thread 40 Nm +10%
*acc. to SAE J514, 37°
ÎPlease note the connection size marked on your product
- Other connection port sizes available on request
7�3 Checking the connection for leak tightness
ÎConnect the fueling nozzle to the WEH®Service receptacle.
ÎSlowly apply the operating pressure to the filling hose and the fueling nozzle.
ÎCheck the fueling nozzle and the connection between the filling hose and the
fueling nozzle for leak tightness. Please refer to Chapter 11. Checking the leak rate
on page 29.
7�4 Fitting the protective sleeve (Pos� 5)
ÎSlide the protective sleeve (Pos. 5) onto the fueling nozzle and secure the protective
sleeve using the three countersunk screws (Pos. 4).
Tightening torque 3 Nm.
Figure 1
A/F(1)
B1
C2
A/F(2)
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8. OPERATION
Please note: The following mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
8�1 Safety instructions for operation
ÎOnly actuate the fueling nozzle when it is connected to the receptacle or a
WEH®Service receptacle .
ÎDo not use excessive force when actuating.
ÎPlease follow the steps in exactly the right order when connecting and disconnect-
ing the fueling nozzle.
ÎThe fueling nozzle may only be connected and disconnected when depressurized.
8�2 Connection
ÎRemove the fueling nozzle from the mounting. The actua-
tion lever (Pos. 3) must be in the OFF position (Figure 2).
ÎPush the fueling nozzle onto the receptacle until it stops
and hold the nozzle in this position (OFF position)
(Figure 3).
Please note: For easier handling, the TK16 H2is equipped
with a swivel joint (Pos. 6).
ÎTurn the actuation lever (Pos. 3) on the fueling nozzle
through 180° to the ON position (Figure 4).
If the actuation lever cannot be turned easily, remove the
fueling nozzle and then reattach it.
- The fueling nozzle is now pressure-tight connected to the
receptacle.
- The fueling process can begin.
Please note: The fueling process can be terminated prema-
turely at any time by turning the actuation lever (Pos. 3) to
the OFF position.
Figure 2
OFFON
Figure 3
Figure 4
OFFON
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8�3 Disconnection
ÎOnce the fueling process is complete, close the fueling
nozzle.
ÎTurn the actuation lever (Pos. 3) on the fueling nozzle
through 180° to the OFF position (Figure 5).
Please note: The area between the receptacle and the actu-
ating unit of the fueling nozzle is completely vented via the
gas recirculation. The fueling nozzle is relieved of pressure in
the OFF position, but the filling hose remains pressurized.
ÎLift the hose on the fueling nozzle slightly and pull the
fueling nozzle straight off the receptacle (Figure 6).
ÎHook the fueling nozzle into the mounting according to the
instructions.
Figure 6
Figure 5
OFFON
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9. INSPECTION | MAINTENANCE
Please note: The following 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 12. Troubleshooting on page 32 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 11. Checking the leak rate on page 29.
- 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 gets into the gas channel (Figure 7).
ÎBefore using the adhesive or the WEH®Threadlocking adhesive, always degrease the
threads/surfaces to be glued with the WEH®Degreasing spray part no. E99-9.
ÎWhen using the adhesive or the WEH®Threadlocking adhesive, the guidelines of the
manufacturer have to be observed, e.g. the curing time of 24 hours.
ÎMake sure that no sealing surfaces or sealing components get in contact with the
adhesive or the WEH®Threadlocking adhesive.
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