Weh TK26 CNG User manual

WEH®- We Engineer Hightech
Type TK26 CNG
Operating instructions ⋅Betriebsanleitung Date: 09/22
WEH®Fueling nozzle for natural gas refueling
WEH®Füllkupplung zur Erdgasbetankung

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 TK26 CNG � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
WEH®Fueling nozzle for natural gas refueling
TYP TK26 CNG � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 38
WEH®Füllkupplung zur Erdgasbetankung
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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 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 18
7.4 Fitting the protective sleeve (Pos. 5) 18
Type TK26 CNG
WEH®Fueling nozzle for natural gas refueling
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The German version is the original.
Manufacturer: WEH GmbH Gas Technology - hereafter referred to as 'WEH'.
8. OPERATION 19
8.1 Safety instructions for operation 19
8.2 Connection 19
8.3 Disconnection 20
9. INSPECTION | MAINTENANCE 21
9.1 Safety instructions for inspection and maintenance 21
9.2 Maintenance intervals 22
9.3 Overview of minimum intervals for inspection and maintenance 23
9.4 Maintenance 24
10. LUBRICATION 29
10.1 Safety instructions for lubrication 29
10.2 Lubrication 29
11. CHECKING THE LEAK RATE 30
11.1 Measuring the leak rate using a concentration meter 30
11.2 Safety instructions for connecting the service receptacle 31
11.3 Checking the leak rate 31
12. EXAMINATION AFTER SEPARATION 33
13. TROUBLESHOOTING 34
14. DISPOSAL 36
15. ACCESSORIES | SPARE PARTS 36
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1. INTRODUCTION
Dear Customer!
Thank you for deciding to use our products.
The WEH®TK26 CNG Fueling nozzle has been developed exclusively for refueling
vehicles with compressed natural gas (CNG).
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 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 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
application 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 lia-
bility 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. Other-
wise, 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 tech-
nical standards. In particular, make sure that you and all users comply with the ap-
plicable 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 ensure 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®TK26 CNG Fueling nozzle has been developed exclusively for refueling
vehicles with compressed natural gas (CNG).
- The WEH®Product is suitable for self-service operation.
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.
ÎWhen used at sea or near the sea, increased salt and moisture content of the air may
cause faster wear and corrosion of the product. Please observe the special mainte-
nance instructions in Chapter 9.2 Maintenance intervals on page 22.
- 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®TK26 CNG Fueling nozzle
TK26 CNG 200 bar TK26 CNG 250 bar
Series Bus /
Truck
Pressure PN Part no�
200 bar 250 bar
TK26 CNG 200 bar X X C1-70708-X01
TK26 CNG 250 bar X X C1-102475-X01
Overview of Pressure Stage/Coding
Overview TN5 CNG 200 bar TN5 CNG 250 bar
TK26 CNG 200 bar X X
TK26 CNG 250 bar X
Please note:
- Fueling nozzles for 200 bar (3,000 psi) are equipped with black impact protection.
- Fueling nozzles for 250 bar (3,600 psi) are equipped with yellow impact protection.
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Product description
TK26 CNG 200 bar
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
B1
4
5
1
2
3
C2
6
1
TK26 CNG 250 bar
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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
C200 acc. to ISO 14469 (P30HD acc. to ANSI NGV1)
PN = 200 bar | PS = 300 bar
C250 acc. to ISO 14469 (P36HD acc. to ANSI NGV1)
PN = 250 bar | PS = 350 bar
Media
temperature range -20 °C to +85 °C
Ambient
temperature range -40 °C to +85°C
Part materials Wear-resistant stainless steel, corrosion-resistant surfaces
Sealing materials Resistant to natural gas
Nozzle type - Type 1 in accordance with ANSI NGV1, Section 3
- Type 1 in accordance with ISO 14469, Section 5
Design Thermally insulating plastic casing and gas recirculation
Weight Approx. 3.4 kg
Conformities /
Tests /
Approvals
Based on ISO 14469
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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
storage time.
Attention: Improper storage of the WEH®Product can significantly reduce the
maximum 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
environmental 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
C1-157623 WEH®TNS5 CNG Service
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/F19
(suitable for the torque wrench) X X
-- Open-ended wrench A/F27
(suitable for the torque wrench) X X
-- Hexagonal bit insert A/F2.5
(suitable for the torque wrench) X X
-- Hexagonal screwdriver A/F2.5 X X
-- Slotted screwdriver X
-- Open-ended wrench A/F14 X
-- Open-ended wrench A/F14
(suitable for the torque wrench) X
-- Vice with plastic jaws X
E99-44923 WEH®Maintenance spray X
E99-90160 WEH®Threadlocking adhesive X
E99-35 WEH®Adhesive X
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7. INSTALLATION
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
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
exclusively to the components delivered by WEH.
ÎThe tightening torques will change according to the thread size when using screw
fittings (see Chapter 15. Accessories | Spare parts on page 36).
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7�2 Installing the filling and venting hose
Please note: Subsequent mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
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 ports.
ÎWhen mounting the filling and venting hose, hold an
open-ended wrench against the wrench 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
venting hose (Figure 1).
Please see the table below for the tightening torque.
Ports Torque
UNF 9/16“-18*male thread 40 Nm +10%
UNF 7/8“-14*male thread 60 Nm +10%
UNF 7/8“-14** female thread 60 Nm +10%
*acc. to SAE J514, 37°
** acc. to SAE J1926
ÎPlease note the connection size marked on your product
- Other connection port sizes available on request
Figure 1
A/F(1)
B1
C2
A/F(2)
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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 30.
ÎAfter completing the leakage test on the fueling nozzle and the filling hose, vent the
system completely.
While venting, check the gas recirculation and the connections to the gas recircu-
lation for leak tightness. Please refer to Chapter 11. Checking the leak rate on page
30.
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.
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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
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.
ÎOnly operate the fueling nozzle when it is connected to a receptacle on the vehicle.
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).
Please note: The TK26 CNG is equipped with a swivel joint
(Pos. 6) for easy handling.
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.
Figure 4
OFFON
Figure 3
Figure 2
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
actuating 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 in the mounting on the
dispenser according to the instructions at the fueling
station.
Figure 6
Figure 5
OFFON
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