Weh TK25 H2 User manual

WEH®- We Engineer Hightech
Type TK25 H2
Operating instructions ⋅Betriebsanleitung Date: 12/22
WEH®Hydrogen fueling nozzle
WEH®Füllkupplung zur Wasserstoffbetankung

Die deutsche Version ist das Original.
Hersteller: WEH GmbH Gas Technology - im Nachfolgenden „WEH“ genannt.
The German version is the original.
Manufacturer: WEH GmbH Gas Technology - hereafter referred to as 'WEH'.
LANGUAGES
TYPE TK25 H2� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
WEH®Hydrogen fueling nozzle
TYP TK25 H2� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32
WEH®Füllkupplung zur Wasserstoffbetankung
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DE

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 15
7.1 Safety instructions for installation 15
7.2 Installing the filling and venting hose 16
7.3 Checking the connection for leak tightness 16
Type TK25 H2
WEH®Hydrogen fueling nozzle
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Operating instructions
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The German version is the original.
Manufacturer: WEH GmbH Gas Technology - hereafter referred to as 'WEH'.
8. OPERATION 17
8.1 Safety instructions for operation 17
8.2 Connection 17
8.3 Disconnection 18
9. INSPECTION | MAINTENANCE 19
9.1 Safety instructions for inspection and maintenance 19
9.2 Maintenance intervals 20
9.3 Overview of minimum intervals for inspection and maintenance 21
9.4 Maintenance 21
10. LUBRICATION 24
10.1 Safety instructions for lubrication 24
10.2 Lubrication 24
11. CHECKING THE LEAK RATE 25
11.1 Measuring the leak rate using a concentration meter 25
11.2 Safety instructions for connecting the service receptacle 26
11.3 Checking the leak rate 26
12. EXAMINATION AFTER SEPARATION 28
13. TROUBLESHOOTING 29
14. DISPOSAL 30
15. ACCESSORIES | SPARE PARTS 30
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1. INTRODUCTION
Dear Customer!
Thank you for deciding to use our products.
The WEH®TK25 H2Fueling nozzle was specifically developed for refueling vehicles with
compressed gaseous hydrogen (CGH2).
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 follow-
ing 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 provid-
ed for illustrative purposes only and may differ in some details from the actual product.
For binding information, please refer to your individual orders.
Abbreviations / Definitions
For explanation of abbreviations and definitions of terms see applicable 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 proper-
ty 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 informa-
tion 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
maintenance. 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
arising 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 qualifi-
cation 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
installation, operation and maintenance of this WEH®Product.
- The WEH®Product and these operating instructions are intended for use by
qualified personnel (see Chapter 1.5). Make these operating instructions available
in particular to the qualified personnel responsible for the individual phases of the
life cycle (especially for storage, installation, operation, inspection and mainte-
nance, troubleshooting and disposal) of the WEH®Product. The qualified personnel
must have read and understood these operating instructions.
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. Tighten-
ing 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.
ÎDo not apply any external forces to the WEH®Product. Therefore, do not lean on the
(connected) WEH®Product, do not hang on the WEH®Product and do not climb on
the WEH®Product under any circumstances. In addition, refrain from hammering
on the WEH®Product or similar. Such force effects can lead to damage to property
and personal injury. Also make sure that the WEH®Product is protected from being
stepped on or run over in any way.
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- The WEH®Product can become very hot or very cold due to the possible fluids
flowing through it, depending on the application and operating situation. In this
regard, observe the national and international regulations on occupational health
and safety to prevent injuries.
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®TK25 H2Fueling nozzle was specifically developed for refueling buses
and trucks with compressed gaseous hydrogen (CGH2).
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.
- When used at sea or in the vicinity of the sea, increased salt and moisture content of
the air may cause faster wear and corrosion of the product. Please observe the spe-
cial maintenance instructions in Chapter 9.2 Maintenance intervals on page 20.
- 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 con-
sidered to be similar to piping. This WEH®Product may not be used as safety
accessory. 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 classification 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
Product overview - WEH®TK25 H2Fueling nozzle
TK25 H225 MPa
Series Bus and
truck
Pressure range Part no�
25 MPa 35 MPa
TK25 H225 MPa X X C1-62529-X01
TK25 H235 MPa X X C1-62527-X1-X01
Overview of Pressure Stage/Coding
Overview TN5 H225 MPa TN5 H235 MPa
TK25 H225 MPa X X
TK25 H235 MPa X
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Product description
Pos� Description
1 Guide bush
2 Cover disc
3 Actuation lever
4 Protection sleeve
Definition of ports
B1 Media inlet
C2 Media outlet
4
1
3
2
C2
B1
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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) 12 mm
Pressure range PN = 25 MPa | PS = 35 MPa
PN = 35 MPa | PS = 45 MPa
Media temperature
range -20 °C to +85 °C
Ambient temperature
range -40 °C to +85 °C
Parts materials Wear-resistant stainless steel, corrosion-resistant surfaces
Sealing material Hydrogen resistant
Design Thermally insulating plastic casing and gas recirculation
Weight Approx. 4.6 kg
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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 theWEH®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 11. Checking the leak rate on
page 25.
> 3 years - Before use, all elastomer seals must be replaced.
ÎFor this, send the WEH®Product to WEH for maintenance.
6. REQUIRED TOOLS
Part No� Description Installation Checking the
leak rate
Mainte-
nance &
Lubrication
C1-157347 WEH®TNS5 H2Service
Receptacle X X
-- Open-ended wrench A/F16 X X
-- Open-ended wrench A/F27 X X
-- Calibrated torque wrench
(suitable for corresponding torque) X X
-- Open-ended wrench A/F16
(suitable for the torque wrench) X X
E99-44923 WEH®Maintenance spray X
E99-90160 WEH®Threadlocking adhesive 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 locks are designed to protect the product and
the connections 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.
ÎBefore installation, check if the counterparts are designed to withstand the assembly
data (see Chapter 7.2 Installing the filling and venting hose) 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 protection caps from the ports.
ÎWhen mounting the filling and venting hose, hold an
open-ended wrench against the wrench size A/F(1) and
A/F(2) (Figure 1).
ÎScrew the media inlet ‘B1’ pressure-tight onto the connec-
tion 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.
Connections Torque
UNF 9/16“-18*male thread 40 Nm +10%
UNF 7/8“-14*male thread 60 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 25.
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 of a vehicle 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.
ÎOnly connect and disconnect the fueling nozzle when it is depressurized.
8�2 Connection
ÎRemove the fueling nozzle from the dispenser. The actuation lever (Pos. 3) must be
in the OFF position (Figure 2).
ÎPush the fueling nozzle onto the receptacle on the vehicle until it stops and hold the
nozzle in this position (OFF position) (Figure 3).
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.
ÎIf present, open the ball valve in the vehicle.
- The fueling process can begin.
Please note: The fueling process can be terminated prematurely at any time by
turning the actuation lever (Pos. 3) to the OFF position.
OFFON
Figure 2 Figure 3 Figure 4
OFFON
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8�3 Disconnection
ÎIf present, close the ball valve in the vehicle.
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).
ÎReplace the fueling nozzle back into the dispenser
mounting according to the instructions at the fueling
station.
.
Figure 5
OFFON
Figure 6
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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
detected, measures as set out in Chapter 13. Troubleshooting on page 29 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 25.
- 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
application 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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ÎObserve the specified tightening torques and bondings during maintenance.
ÎOnly apply pressure to the fueling nozzle if it is connected to a receptacle on the
vehicle. For purging or other maintenance work such as leak testing, connect the
fueling nozzle to a WEH®Service receptacle (see Chapter 11. Checking the leak rate
on page 25).
Attention: If you apply pressure to the fueling nozzle without a service receptacle, the
fueling nozzle may be damaged. Therefore always use a WEH®Service receptacle.
9�2 Maintenance intervals
ÎInspect the WEH®Product at regular intervals depending on the respective oper-
ating conditions, but at least every 3 months. After 20,000 cycles or 3 years at the
latest, depending on what happens first, starting from the date of delivery (invoice/
goods issue date by WEH or the distributor), the WEH®Product must be sent to
WEH for maintenance.
These intervals can also be significantly shorter, which depends especially on your
individual application/use. Therefore, in case of abnormalities – especially during
regular inspection – send the WEH®Product immediately to WEH for maintenance.
Products that are used at sea or in the vicinity of the sea must be sent to WEH for
maintenance after one year at the latest.
If the WEH®Product is not regularly inspected and sent to WEH for maintenance,
leakage may occur and under certain circumstances this may result in failures
and/or accidents.
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