Weh TW221 User manual

WEH®- We Engineer Hightech
Type TW221
Operating instructions ⋅Betriebsanleitung
WEH®Connector for pressure and vacuum tests in straight tubes
and in bores
WEH®Adapter zur Druck- und Vakuumprüfung in Glattrohren und
in Bohrungen

Die deutsche Version ist das Original.
Hersteller: WEH GmbH Verbindungstechnik - im Nachfolgenden „WEH“ genannt.
LANGUAGES
TYPE TW221 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
WEH®Connector for pressure and vacuum tests in straight tubes and in bores
TYP TW221 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32
WEH®Adapter zur Druck- und Vakuumprüfung in Glattrohren und in Bohrungen
AE
DE
The German version is the original.
Manufacturer: WEH GmbH Precision Connectors – hereinafter referred to as “WEH”.

Type TW221
WEH®Connector for pressure and vacuum tests in straight tubes
and in bores
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 media line 16
7.3 Checking the connection for leak tightness 16
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The German version is the original.
Manufacturer: WEH GmbH Precision Connectors - hereafter referred to as 'WEH'.
8. OPERATION 17
8.1 Safety instructions for operation 17
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 21
9.4 Maintenance 22
10. LUBRICATION 28
10.1 Safety instructions for lubrication 28
10.2 Lubrication 28
11. TROUBLESHOOTING 29
12. DISPOSAL 31
13. ACCESSORIES | SPARE PARTS 31
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1. INTRODUCTION
Dear Customer,
Thank you for deciding to use our products.
The WEH®TW221 Connector has been developed for pressure and vacuum testing in
straight tubes and in bores.
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 instruc-
tions 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 are responsible for the correct operation 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 replace-
ment 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 perfor-
mance, 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.
Caution: Incorrect application poses a risk to the user's health and can cause property
damages. The consequences of incorrect application could include the following:
- the connector or parts of the connector become loose under pressure
- media that may be under pressure, hot or toxic, can escape
- connection hoses vibrate dangerously
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.
- It is assumed that only transport and storage facilities suitable for the storage of the
WEH®Product are used.
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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®TW221 Connector has been developed for pressure and vacuum testing
in straight tubes and in bores. The connector comes in many different sizes and
forms.
ÎOnly use the WEH®Product if you fulfill the following specifications:
- The required roundness of the internal tube diameter is max. 0.25mm
Contact WEH if the application lies outside the specified values or if you have any
questions regarding the surface finish.
- The test piece and the seals must be dry during testing. If they are not dry, a
pressure-tight connection can not be made and the connector will not hold in the
test piece.
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® Connector has been specially developed for your application and require-
ments that you specified when placing your order. The connector only works properly
together with your connection and may only be attached to this connection.
- 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.
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3. PRODUCT OVERVIEW / PRODUCT DESCRIPTION
WEH®TW221 Connector body size 1 & body size 2
Pos� Description
1 Base unit
2 Clamping lever
3Peg
4 Key ring
5 Spacer*
6 O-ring (shaft)
7 Front seal**
8 Disc
9 Disc
10 Shaft
* only for body size 1
** from body size 2 with 2 front seals
Definition of ports
B1 Media inlet
10
9
5
6
8
7
1
7
B1
2
4
3
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WEH®TW221 Connector body size 3
Pos� Description
1 Base unit
2 Clamping lever
6 O-ring (shaft)
7 Front seal
8 Disc
9 Disc
10 Shaft
Definition of ports
B1 Media inlet
1
7
B1
2
10
9
6
8
7
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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) 8.6mm
Max. allowable operat-
ing pressure PS 1 - 3 bar
Temperature range +5°C to +80°C
Leak rate 1 x 10-3 mbar x l/s
Part materials Corrosion-resistant stainless steel, anodised aluminium
Sealing materials Front seal in SBR
Actuation Manual actuation via clamping lever
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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 appropriate storage period applies from the date of delivery (i.e. the date
of invoicing or goods issue date as recorded by WEH or its distributor). 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 15.
> 3 years - Before use, all elastomer seals must be replaced.
ÎFor this, send the WEH®Product to WEH for maintenance.
ÎStore the WEH®Connector with the clamping lever released. The clamping lever
must not be actuated. The service life of the seals will be shortened if the seal is left
in the clamped position for a long time without a test piece.
6. REQUIRED TOOLS
Part no� Description Installation Maintenance &
Lubrication
-- Suitable open-ended spanner
(suitable for the relevant spanner widths) X
-- Calibrated torque wrench
(suitable for the corresponding torque) X
-- Suitable hexagonal screwdriver
(suitable for the corresponding Allen key) X
W136538 WEH®O-ring picker set*X
E99-44923 WEH®Maintenance spray X
E99-21 WEH®Threadlocking adhesive X
*The WEH® O-ring picker is manufactured from plastic and has to be considered as a
consumable product.
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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 serve the purpose of protecting the
product and connection 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.
ÎAvoid using excessively short media lines and narrow bending radii. Lateral forces
may cause leakages or damage to components and make it more difficult to attach
the WEH®Connector properly.
ÎUse arrestor cables, partitions, etc. for additional safety where being used for haz-
ardous applications or under hazardous conditions.
ÎUSIT rings should be used to seal the ports.
ÎBefore installation, check if the counterparts are designed to withstand the assembly
data (see Chapter 7.2 Installing the media line) that WEH determined for this
WEH®Product.
Note: The indicated assembly data (tightening torques, assembly turns etc.) are values
that apply only to the components delivered by WEH.
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7�2 Installing the media line
Please note: Subsequent mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
ÎUnscrew the protection cap from the port.
ÎWhen mounting media hose line, hold an open-ended
spanner against the spanner flat AF(1) (Figure 1).
ÎScrew the ‘B1’ media inlet pressure-tight to the port for the
media line (Figure 1).
Tightening torque: 10Nm ± 10% (G1/8“ female thread).
7�3 Checking the connection for leak tightness
ÎConnect the connector to a closed test piece.
ÎSlowly apply the operating pressure to the connector and media line.
Caution: The test piece must be closed.
ÎCheck the connector, the connection to the media line and the connection to the test
piece for leak tightness.
Attention: Do not use a leak detection spray that contains ammonia, since this could
cause corrosion of the connector.
Figure 1
A/F(1)
B1
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8. OPERATION
8�1 Safety instructions for operation
Please note: Subsequent mentions of descriptions and position numbers refer to
Chapter 3. Product overview / product description on page 10.
ÎApply pressure to the WEH®Connector only once it has been connected to a test
piece.
ÎDo not use excessive force when actuating.
ÎFollow the steps in exactly the right order when connecting and disconnecting the
WEH®Connector.
ÎAttach and detach the WEH®Connector only when it is not under pressure.
ÎConnect the WEH®Connector only to test pieces in full working order.
ÎAlign the WEH®Connector correctly with the test piece to prevent damage to the
front seal caused by any sharp edges that the test piece may have.
ÎDo not actuate the WEH®Connector without a test piece. The seals can be damaged
without the test piece connected.
ÎOnce the connection has been made, always test the connection by tugging a little
on the WEH®Connector to make sure that is fully engaged and that the seals are
gripping correctly before introducing the pressurized test medium.
ÎThe WEH®Connector is designed in such a way that it tightens and seals directly
when connected to the test piece. Keep fingers and other objects away from the
seals when actuating the connector.
Caution: Possible consequences of non-compliance are:
– Risk of fingers being crushed when connecting
– Risk to human safety and risk of damage to property by parts detaching at
high pressure
– Risk to human health by media being released at high pressure
– Risk to human safety by hoses not being secured
ÎThe WEH®Connector is not fitted with an integrated shut-off valve and thus will not
prevent loss of test medium when disconnecting. Therefore it is important to discon-
nect the connector only under absolutely safe conditions.
ÎPlease observe the actuation direction of the clamping lever (Pos. 2) for body size 1 and
2. In the standard arrangement, the clamping lever is actuated downwards and the ‘B1’
media inlet faces upwards. It is possible to convert the clamping lever for upwards actu-
ation to suit the application. Please refer to Chapter 9.4.2 Conversion of the clamping
lever (Pos. 2) on page 26.
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ÎMake sure that the test piece and the seals are dry during testing. If they are not dry,
a pressure-tight connection can not be made and the connector will not hold in the
test piece.
8�2 Connection
ÎMove the clamping lever (Pos. 2) to the straight starting
position (Figure 2).
ÎGrip the connector by its base unit (Pos. 1) and plug it up
to the stop straight into the test piece (Figure 3). Doing
so will prevent any damage to the front seal caused by
any sharp edges on the test piece and ensure a correct
connection.
Attention: Insert the connector carefully and not with force
into the test piece.
ÎActuate the clamping lever (Pos. 2) by 90° downwards
(Figure 4). The connector tightens itself to the test piece
and creates a pressure-tight connection.
Attention: Make sure that the seals on the test piece grip
correctly, that the connector is seated properly (it must not
wobble) and that the pressure-tight connection has been
made. Only then is the connector connected correctly.
Otherwise the connector may spring out of place and
medium may escape.
ÎPull lightly on the connector (red arrow Figure 5) in the
direction opposite that of the connection to make sure
that the connector is firmly in place.
- The connector is now connected pressure-tight to the test
piece.
ÎTo start the testing procedure, apply pressure to media
inlet ‘B1’.
Figure 2
Figure 3
Figure 4
Figure 5
pull backwards
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8�3 Disconnection
ÎAfter the end of the testing procedure, fully vent the media
line.
Caution: First depressurize the system before releasing
the connection. The integrated safety system will not let
you open the pressure-aided seals when the system is
pressurized.
ÎGrip the connector by its base unit (Pos. 1).
Caution: Keep your fingers away from the piston
(Figure 6). You can crush or squeeze your fingers when
actuating the clamping lever (Pos. 2).
ÎActuate the clamping lever (Pos. 2) by 90° back to its initial
position (Figure 6).
ÎMove the connector slightly in the direction of the test piece
(Figure 7). The connection to the test piece is released and
the connector can be removed by pulling it straight back.
Attention: In the event that you cannot remove the connec-
tor from the test piece:
- Wait a few moments
- Never use excessive force
- Do not use any tools (e.g. hammer)
- Make sure that the connector is depressurized
Figure 7
Crushing hazard
area
Figure 6
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9. INSPECTION | MAINTENANCE
Please note: Subsequent 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 11. 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 7. Installation on page 15.
- 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 enters the gas channel.
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.
ÎObserve the specified tightening torques and bondings during maintenance.
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