Weh TW800 User manual

WEH®- We Engineer Hightech
Type TW800
Operating instructions ⋅Betriebsanleitung
The WEH®Connector for pressure and function test of
components with beads, rims, collar, flange, stub and male threads
WEH®Adapter zur Druck- und Funktionsprüfung an Bauteilen mit
Sicken, Bördeln, Bund, Flansch, Stutzen und Außengewinde

Die deutsche Version ist das Original.
Hersteller: WEH GmbH Verbindungstechnik - im Nachfolgenden „WEH“ genannt.
LANGUAGES
TYPE TW800 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
The WEH®Connector for pressure and function test of
components with beads, rims, collar, flange, stub and male thread
TYP TW800 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 32
WEH®Adapter zur Druck- und Funktionsprüfung an
Bauteilen mit Sicken, Bördeln, Bund, Flansch, Stutzen und Außengewinde
AE
DE
The German version is the original.
Manufacturer: WEH GmbH Precicion Connectors – hereinafter referred to as “WEH”.

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 11
5. STORAGE 12
5.1 Safety instructions for proper storage 12
5.2 Storage 13
6. REQUIRED TOOLS 13
Type TW800
The WEH®Connector for pressure and function test of compo-
nents with beads, rims, collar, flange, stub and male thread
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Operating instructions
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The German version is the original.
Manufacturer: WEH GmbH Precision Connectors – hereinafter referred to as “WEH”.
7. INSTALLATION 14
7.1 Safety instructions for installation 14
7.2 Installing the media hose line 15
7.3 Checking the connection for leaks 15
8. OPERATION 16
8.1 Safety instructions for operation 16
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 Disassembly 24
10.3 Lubrication 25
10.4 Assembly 26
11. TROUBLESHOOTING 27
12. DISPOSAL 29
13. ACCESSORIES | SPARE PARTS 29
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1. INTRODUCTION
Dear Customer,
Thank you for deciding to use our products.
The WEH®TW800 Connector has been developed for pressure and function test of
components with bead, rim, collar, flange, stub or male thread.
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
For explanation of abbreviations and definitions of terms see Technical Appendix of the
corresponding catalog or www.weh.com
Definition of signal words
Caution: Sections marked ‘Caution’ warn you of hazards that could result in minor,
usually reversible, personal injury if you do not comply with the 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 Qual-
ity 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
application 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
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 for endangering yourself and third parties.
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Operating instructions AE

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, certifi-
cates and approvals have been obtained.
ÎThese operating instructions should be provided to anyone responsible for the
installation, operation and maintenance of this WEH®Product.
Caution: Incorrect application poses a risk to the useres’ 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. Tight-
ening 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®TW800 Connector has been developed for pressure and function test
of components with bead, rim, collar, flange, stub or male thread. The connector
comes in many different sizes and forms.
- The WEH®Connector is not suitable for emptying containers under pressure.
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
requirements that you specified when placing your order. The connection 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
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
Pos� Description
1 Sliding sleeve
2 Lower part
7 Front seal
Definition of ports
B1 Media inlet
1
7
B1
2
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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
Max. allowable operat-
ing pressure PS Vacuum up to 50 bar
Temperature range +5°C to +80°C
Leak rate 1 x 10-3 mbar x l/s
Part materials Wear-resistant stainless steel, corrosion-resistant surfaces
Sealing materials Front seal in NBR
Design With or without integrated shut-off valve
Actuation Manual actuation via sliding sleeve
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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 (especially against direct sunlight), oxygen,
ozone, heat, UV rays, solvents 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 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 sales partner). 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 ageing 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 14.
> 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 Maintenance &
Lubrication
-- Suitable open-ended spanner
(suitable for the relevant spanner widths) X
-- Suitable calibrated torque wrench
(suitable for the corresponding torque) X
-- Suitable open-ended spanner insert (suitable for the relevant spanner widths and
torque spanner) X
-- Suitable slotted screwdriver X
W136538 WEH®O-ring picker set*X
E99-40 WEH®Lubricant 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
depressurized condition.
ÎAvoid using excessively short media hose 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
hazardous applications or under hazardous conditions.
ÎUSIT rings should be used to seal the ports.
ÎPrior to installation, check that the counterparts are designed in accordance with the
assembly data (see Chapter 7.2 Installing the media hose line) specified for the WEH®
Product by WEH.
Note: The assembly data (torques, assembly turns etc.) are values which apply
exclusively to the components delivered by WEH.
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7�2 Installing the media hose 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 hose line (Figure 1).
For the tightening torque, please refer to the table below.
Note: For NPT thread, first wrap Teflon tape round the
tapered screw fitting (1.5layers). Then screw the fitting
finger-tight into the connection and install it in accor-
dance with the information in the table below.
Connections
female thread
Torque
G thread
Assembly turns
NPT thread*
1/8" 10 Nm ± 2 Nm 2.0–3.0
1/4" 30 Nm ± 2 Nm 2.0–3.0
3/8" 40 Nm ± 2 Nm 2.0–3.0
1/2" 50 Nm ± 2 Nm 2.0–3.0
3/4" 60 Nm ± 2 Nm 2.0–3.0
* One turn corresponds to 360°
ÎPlease note the connection size marked on your product.
- Other connection sizes are available on request.
7�3 Checking the connection for leaks
ÎConnect the connector to a closed test piece.
ÎSlowly apply the operating pressure to the connector and media hose line.
Caution: The test piece must be closed.
ÎCheck the connector, the connection to the media hose 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
AF(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.
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 clamping
jaws are gripping correctly before introducing the pressurized test medium.
ÎThe clamping jaws of the WEH®Connector are designed to grip the test piece. Keep
fingers and other objects away from the clamping jaws when actuating the
connector.
Caution: Possible consequences of failing to observe this instruction may include:
– Risk of fingers being crushed while connecting
– Risk of personal injury and damage to property by parts that may become
detached under high pressure
– Risk of personal injury by media escaping at high pressure
– Risk to human safety by hoses not being secured
ÎFor WEH®Connectors without an integrated shut-off valve, testing medium may
escape when disconnecting. Therefore it is important to disconnect the connector only
under absolutely safe conditions.
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8�2 Connection
ÎGrip the connector by its sliding sleeve (Pos. 1).
ÎBe careful to place the connector straight onto the test piece. Doing so will prevent
any damage to the front seal caused by any sharp edges on the test piece and
ensure a correct connection.
ÎSlide the connector’s sliding sleeve forward (Pos. 1) onto
the test piece (Figure 2). The connector must engage with
a clearly audible click. The circlip must be visible (Figure 3)
and the outer edges of the external diameter of the clamp-
ing jaws must no longer be visible (Figure 4 and Figure 5).
The integrated shut-off valve, if provided, is pushed open by
connecting the connector.
Attention: If the connector does not click into place, the
outer edges of the external diameter of the clamping jaws
are visible or the circlip is not visible, then the connector
is not correctly connected. The connector may spring out
of place and medium may escape.
ÎPull gently on the lower part of the connector (Pos. 2)
(Red arrow Figure 6) in the direction opposite that of the
connection to make sure that the connector is properly
connected.
- 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 5Figure 4
Figure 6
pull backwards
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8�3 Disconnection
ÎAfter the end of the testing procedure, fully vent the media
hose line.
Caution: First depressurize the system before releasing
the connection.
ÎGrip the connector by its sliding sleeve (Pos. 1).
ÎPull the sliding sleeve back (Pos. 1) (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
connector from the test piece:
- Wait a few moments
- Never use excessive force
- Do not use any tools (e.g. hammer)
Figure 7
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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
detected, measures as set out in Chapter 11. Troubleshooting on page 27 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 14.
- 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: Use only oil-free compressed air to blow away the dirt.
Note: Make sure that no cleaning agent enters the gas channel.
ÎAvoid contact with any mineral oil-based chemicals. These can contaminate and
damage the WEH®Product.
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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.
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.
- For devices with cold and hot water applications, the sealing disc of the connector
must regularly be lubricated with WEH®High performance grease paste
part no. E99-40 to prevent dry-running and ensure correct functioning. Indications
of
dry-running could include stiffness when connecting and disconnecting. Depending
on the degree of lubrication, it may be necessary for the operator to set a suitable
maintenance schedule independently.
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