Weh TSA6 CNG User manual

WEH®- We Engineer Hightech
Type TSA6 CNG
Operating instructions ⋅Betriebsanleitung Date: 09/22
WEH®Inline-breakaway coupling for bus and truck natural gas
fueling stations
WEH®Inline-Abreißsicherung für Bus- und LKW-Erdgastankstellen

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 TSA6 CNG � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
WEH®Inline-breakaway coupling for bus and truck natural gas fueling stations
TYP TSA6 CNG � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 36
WEH®Inline-Abreißsicherung für Bus- und LKW-Erdgastankstellen
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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 13
5. STORAGE 14
5.1 Safety instructions for proper storage 14
5.2 Storage 15
6. REQUIRED TOOLS 16
7. INSTALLATION 17
7.1 Safety instructions for installation 17
7.2 Removing the receptacle insert (Pos. 7) from the coupling body 17
7.3 Installing the filling and venting hose 18
7.4 Inserting the receptacle insert (Pos. 7) into the coupling body 19
7.5 Checking the connection for leak tightness 19
7.6 Install TSF5 CNG pre-filter on the media inlet “B1” (optional) 20
Type TSA6 CNG
WEH®Inline-breakaway coupling for bus and truck natural gas
fueling stations
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The German version is the original.
Manufacturer: WEH GmbH Gas Technology - hereafter referred to as 'WEH'.
8. INSPECTION | MAINTENANCE 21
8.1 Safety instructions for inspection and maintenance 21
8.2 Maintenance intervals 22
8.3 Overview of minimum intervals for inspection and maintenance 22
8.4 Maintenance 23
9. CHECKING THE LEAK RATE 27
9.1 Measuring the leak rate using a concentration meter 27
9.2 Checking the leak rate 28
10. INSPECTION AFTER SEPARATION | RECOMMISSIONING 29
10.1 Safety instructions for venting 29
10.2 Venting the hose line 29
10.3 Examination after separation 30
10.4 Recommissioning 31
11. TROUBLESHOOTING 32
12. DISPOSAL 33
13. ACCESSORIES | SPARE PARTS 33
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1. INTRODUCTION
Dear Customer!
Thank you for deciding to use our products.
The WEH®TSA6 CNG Breakaway coupling was specifically developed for bus and truck
natural gas fueling stations for installation between filling hoses or filling and venting
hoses. The breakaway coupling consists of a coupling body, a receptacle insert and an
optional gas recirculation.
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 / 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
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 WEH®Product
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 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®TSA6 CNG Breakaway coupling was specifically developed for bus and
truck natural gas fueling stations for installation between filling hoses or filling and
venting hoses.
- When used as intended, The WEH®Breakaway coupling separates the connection
between the dispenser and hose in a controlled manner if unexpected tractive force
occurs, for example due to a vehicle driving off while it is still connected to the fueling
nozzle.
Immediately after separation, the coupling body and the receptacle insert are sealed
to be pressure-tight.
- When 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
maintenance instructions in Chapter 8.2 Maintenance intervals on page 22.
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
considered 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®TSA6 CNG Breakaway coupling
TSA6 CNG without
gas recirculation
TSA6 CNG with
gas recirculation
Product type with gas
recirculation
without gas
recirculation
Pressure range Part no�
200 bar 250 bar
TSA6 CNG
X X C1-71057-X1-X01
X X C1-78834-X01
X X C1-102493-X01
X X C1-76955-X01
X X C1-102492-X01
X X C1-114634-X01
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Product description
TSA6 CNG without gas recirculation
Pos� Description
1 Coupling body
2 Eccentric actuator
3 Rubber protection rear
7 Receptacle insert
Definition of ports
B1 Media inlet
B2 Media outlet
B1
7
1
2
B2
3
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TSA6 CNG with gas recirculation
Pos� Description
1 Coupling body
2 Eccentric actuator
5 Holding flange
6 Gas recirculation
7 Receptacle insert
Definition of ports
B1 Media inlet
B2 Media outlet
C1 Gas recirculation
C2 Gas recirculation
B1
7
1
2
B2
6
5
C1
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.
Characteristics Basic version
Nominal bore (DN) 12 mm
Pressure range PN = 200 bar | PS = 300 bar
PN = 250 bar | PS = 350 bar
Temperature range -40 °C to +85 °C
Breakaway force 222 - 660 N
Part materials Wear-resistant stainless steel, aluminium and corrosion-resistant
surfaces
Sealing materials Natural gas compatible
Design With or without gas recirculation
Weight Approx. 2.0 kg (without gas recirculation)
Approx. 2.2 kg (with gas recirculation)
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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 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 9. Checking the leak rate on
page 27.
> 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 Mainte-
nance
Recommis-
sioning
-- Open-ended wrench A/F17 X X
-- Open-ended wrench A/F19 X X
-- Open-ended wrench A/F30 X X X
-- Open-ended wrench A/F46 X X
-- Calibrated torque wrench
(suitable for corresponding torque) X X
-- Allen key A/F6 X X X
-- Hexagonal screwdriver A/F2 X
-- Hexagonal bit insert A/F2
(suitable for the torque wrench) X
W136538 WEH®O-ring picker set
(consisting of 3x Part No. E98-101969) X
E34-70007 WEH®Assembly tool X
E34-70008 WEH®Assembly tool 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
depressurized condition.
ÎBefore installation, check if the counterparts are designed to withstand the assembly
data (see Chapter 7.3 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.
- The tightening torques will change according to the thread size when using
screw fittings (see Chapter 13. Accessories | Spare parts on page 33).
7�2 Removing the receptacle insert (Pos� 7) from the coupling body
ÎTurn the eccentric actuator (Pos. 2) by 180° using an Allen key A/F6 (Figure 11)
the clamping jaws will open
ÎRemove the receptacle insert (Pos. 7).
ÎClose the clamping jaws by turning back the eccentric actuator (Pos. 2) using an
Allen key A/F6.
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7�3 Installing the filling and venting hose
ÎUnscrew the protection caps from the ports.
ÎWhen mounting the filling and venting hose, the media line
and the gas recirculation onto ports "B1", "B2", "C1" and
"C2", hold an open-ended wrench against the wrench flat
A/F(1), A/F(2), A/F(3) and A/F(4) (Figure 1 and Figure 2).
ÎConnect the media inlet "B1" to the filling hose of the
fueling station (Figure 1) in a pressure-tight manner.
See the table below for information regarding tightening
torque.
ÎConnect the gas recirculation "C2", if provided, to the
venting hose of the fueling station (Figure 1) in a
pressure-tight manner.
See the table below for information regarding tightening
torque.
ÎScrew the media outlet "B2" onto the connection port of the
filling hose (Figure 2) in a pressure-tight manner.
For the tightening torque, please refer to the table below.
ÎScrew the gas recirculation "C2", if provided, onto the connection port of the venting
hose (Figure 2) in a pressure-tight manner.
For the tightening torque, please refer to the table below.
Ports Torque
UNF 7/16“-20*male thread 20 Nm +10%
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 sizes available on request
Figure 1
A/F(1)
B1
C2
A/F (4)
Figure 2
A/F(2)
B2 AF (3)
C1
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7�4 Inserting the receptacle insert (Pos� 7) into the coupling body
ÎBefore inserting the receptacle insert (Pos. 7), check both
sealing elements (o-ring and back-up ring, Figure 3) for
correct installation direction, proper position and any
damages.
ÎTurn the eccentric actuator (Pos. 2) by 180° using an
Allen key A/F6 (Figure 11)
the clamping jaws will open
ÎPlace the receptacle insert (Pos. 7) with mounted filling hose into the coupling body
(Pos. 1) and, if provided, onto the gas recirculation (Pos. 6).
ÎClose the clamping jaws by turning back the eccentric actuator (Pos. 2) using an
Allen key A/F6.
ÎBy gently pulling on the filling hose, check that the clamping jaws are firmly
positioned around the receptacle insert (Pos. 7).
7�5 Checking the connection for leak tightness
ÎSlowly apply the operating pressure to the media inlet, breakaway coupling and
filling hose.
ÎCheck the breakaway coupling and the connections to the breakaway coupling for
leak tightness. Please refer to Chapter 9. Checking the leak rate on page 27.
ÎAfter completing the leakage test on the breakaway coupling, vent the system
completely.
O-ring
Back-up ring
Figure 3
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7�6 Install TSF5 CNG pre-filter on the media inlet “B1” (optional)
ÎObserve the flow direction on the filter housing of the TSF5
CNG. The flow direction is marked with an arrow (see red
arrow in Figure 4).
ÎScrew the media outlet “B2” to the media inlet “B1” of the
TSA6 CNG in a pressure-tight manner.
For the tightening torque please refer to the table Page
18.
ÎConnect the media inlet "B1" to the filling hose of the fueling station (Figure 4) in
a pressure-tight manner. See the table for information regarding tightening torque
Page 18.
Note: When using the TSA6 CNG with gas recirculation, the filling hose to be
connected to the port “B1” must be shorter by the equivalent length to the TSF5 CNG
prefilter installed on the system. WEH provides suitable filling hoses for this purpose.
Note: The full installation procedure is described in Chapter 7.3.
Figure 4
B1
B2
Fueling nozzle Hose set TSF5 CNG filter
TSA6 CNG breakaway coupling Hose set
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