Weh TSA1 H2 70 MPa Operating Instructions Manual

Brand: Weh

Model: TSA1 H2 70 MPa

Type: Operating Instructions Manual

D-2009/09/00712-8-3 | Date: 08/2019

OPERATING INSTRUCTIONS

Type TSA1 H

70 MPa

Breakaway coupling for hydrogen refuelling

at car refuelling stations

WEH

- We Engineer Hightech

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 2

D-2009/09/00712-8-3

CONTENTS

PLEASE NOTE

�� 3

1 GENERAL SAFETY INSTRUCTIONS

�� 3

2 APPLICATION

�� 4

3 INSTALLATION

�� 5

4 EXAMINATION AFTER SEPARATION

�� 8

5 ACCESSORIES | SPARE PARTS

�� 8

6 STORAGE

�� 8

7 MAINTENANCE

�� 9

8 EXAMINATION OF LEAK RATE

�� 10

9 RECOMMISSIONING

�� 11

10 DIMENSIONS

�� 13

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 3

D-2009/09/00712-8-3

Dear Customer!

Thank you for deciding to use a WEH

Product.

The WEH

TSA1 H

70 MPa breakaway coupling has been developed especially for direct installation

at car refuelling stations. The breakaway coupling consists of the breakaway coupling body,

the receptacle insert, a filter and the dispenser mounting system.

The TSA1 H

70 MPa for fuelling nozzles with data interface additionally contains a data cable for

the data interface.

Each delivery must contain:

a) A delivery note

b) An original WEH test report (this does not apply to spare parts)

c) WEH operating instructions

For missing documents, please contact WEH.

Our ‚General Terms and Conditions‘ apply.

Read these operating instructions carefully and follow them whilst using the WEH

Product�

The statements in these instructions correspond to the state of knowledge at the time of prin-

ting� Failure to observe these instructions may result in a loss of warranty� Any variations to

these instructions have to be confirmed by the WEH QA management in writing�

Violation of WEH operating instructions will result in a loss of warranty and in addition the

WEH GmbH will accept no liability for consequential damage caused to persons or property�

PLEASE NOTE

1 GENERAL SAFETY INSTRUCTIONS

For your own safety, please observe the following instructions�

1�1 Please conform to any relevant legal directives, such as for instance any national legisla-

tion on safety and health at work. Observe the relevant approval standards and directives.

1�2 These operating instructions should be provided to each person responsible for installati-

on, operation and maintenance of the product.

1�3 If instructions are not completely understood by operators, contact WEH before attemp-

ting use of the product.

1�4 Where dangerous operating conditions exist, appropriate safety measures must be taken.

1�5 In case of damage and queries concerning the proper functioning of the product, do not

use the product until clarification has been sought. The product should only be dis-

mantled by WEH.

1�6 Service personnel as defined by these instructions are persons able to evaluate the work

entrusted to them and to recognize possible dangers according to their knowledge and

experience and their knowledge of the standards applicable.

1�7 The WEH GmbH is not responsible for any damage resulting from factors outside their

control.

1�8 Transportation and storage facilities suitable for protection of the product must be used

at all times.

1�9 WEH

Products may only be repaired by the manufacturer. Please contact us.

1�10 Observe the torques indicated in these operating instructions. Tightening with a higher

torque can result in fracture damage when the system is pressurized.

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 4

D-2009/09/00712-8-3

2 APPLICATION

The application is defined in the catalogue and in the accompanying product documentation.

Please check that the product marking, delivery note and test report comply with the applica-

tion.If you are not certain about correct installation please contact us before using the equip-

ment.

2�1 Safety instructions for application

2�1�1 Ensure the proper use: The product may be used only if the specified operating

pressure and temperature are not exceeded, and the design criteria and media

defined in the order are complied with. Please check that the product documen-

tation supplied corresponds to the product marking.

2�1�2 Ensure that the connection sizes comply with those of the product. Please check

that the product documentation supplied corresponds to the product marking.

2�1�3 Suitability for application: When selecting a component, the total system design

must be considered to ensure safe, trouble-free performance. The correct se-

lection of a component, material, temperature, pressure range as well as proper

installation, operation and maintenance are the responsibility of the customer.

2�1�4 Do not use this system for media other than gaseous, compressed hydrogen

(CGH

) up to the admitted pressure ranges (see table, page 14) and a temperature

range of -40 °C up to +85 °C.

2�1�5 This WEH

Product is generally and exclusively classified as pressure accessory

for piping in accordance with Article 2 (5) of the Pressure Equipment Directive

2014/68/EU. This WEH

Product may not be used (i) as safety accessory or (ii) for

vessels as defined by the Pressure Equipment Directive 2014/68/EU. Therefore, the

application of this WEH

Product must comply with the classification as pressure

accessory for piping. The assessment with regard to a different classification can,

however, be made on request.

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 5

D-2009/09/00712-8-3

3 INSTALLATION

Definition ports

Media inlet

Media outlet

TSA1 H

70 MPa

Breakaway coupling

body

2 Eccentric actuator

3 Filter (internal)

4 Receptacle insert

5 Mounting

6 Guide tube

7 Fixing elements

8 Retaining brackets

9 Data cable

TSA1 H

70 MPa incl. dispenser mounting

TSA1 H

70 MPa incl. dispenser mounting, for data interface

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 6

D-2009/09/00712-8-3

Pin assignment of data cable

Colour Signal

White Data +

Black Data -

Brown PWR + 5V (conductor)

Blue

GND (ground) |

(neutral conductor)

Tinned shield Housing GND (ground)

Brown

Blue

White

Black

tinned drain wire

tinned shield

3�1 Safety instructions for installation

3�1�1 Please check that the specifications in the product documentation and the pro-

duct marking conform to the application.

3�1�2 Check the product for any damage in transit.

3�1�3 Check that the hoses are depressurized during installation. The hoses have to be

depressurized via the dispenser for every actuation.

3�1�4 The torques will change when using other fittings (see Chapter 5 – Accessories |

Spare Parts) depending on the thread size. Please contact us!

3�1�5 The assembly data indicated (tightening torques, assembly turns etc.) are max.

values and only valid for components delivered by WEH. The customer is respon-

sible to check if his counterparts withstand these max. values determined by

WEH.

3�2 Installation

The WEH

TSA1 H

70 MPa Breakaway Coupling has been developed especially for direct

installation at car refuelling stations.

3�2�1 Loosen the allen fixing elements (pos. 7) with an allen key (A/F 5). Thus the

retaining brackets (pos. 8) surrounding the breakaway coupling are loosened,

allowing the removal of the breakaway coupling from the mounting (pos. 5).n.

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 7

D-2009/09/00712-8-3

Back-up ring

O-ring

Figure 1

3�2�2 Fix the mounting (Pos. 5) to the dispenser at the fixing bores (see figure below).

The mounting must be fixed at a position that is able to withstand the forces

arising in case of an accidental deployment. The fueling station manufacturer is

responsible to make sure that the torn-off hose part is not retained by dispenser

components.

3�2�3 Turn the eccentric actuator (pos. 2) with an allen key (A/F 6) by 180° (see drawing

page 11)  the clamping jaws open. Remove the receptacle insert (pos. 4).

Please note: When reinstalling the receptacle insert (Pos. 4), please observe the

correct installation direction of the sealing components (O-ring and back-up ring)

and make sure that they are properly seated (see figure 1). Before reinstalling,

check the sealing components for damage.

Turn the eccentric actuator (pos. 2) by 180°  the clamping jaws close.

3�2�4 Connect the media outlet ‘B2’ at the receptacle inlet (pos. 4) pressure-tight to the

filling hose end (towards the vehicle) (for torque settings see adjacent table).

3�2�5 Insert the receptacle insert (pos. 4), with the filling hose connected, through the

guide tube (pos. 6) of the mounting (pos. 5).

3�2�6 Connect the media inlet ‘B1’ pressure-tight to the media port of the dispenser

(for torque settings see adjacent table).

3�2�7 Reinsert the breakaway coupling through the retaining brackets (pos. 8). The

eccentric actuator (pos. 2) must be free to allow actuation. Tighten the retaining

brackets (pos. 8) with an allen key (A/F 5) (see figure 2).

3�2�8 Turn the eccentric actuator (pos. 2) with an allen key (A/F 6) by 180° (see drawing

page 12)  the clamping jaws open.

3�2�9 Insert the receptacle insert (pos. 4), with its filling hose connected, into the break-

away coupling. Rotate the eccentric actuator (pos. 2) with an allen key (A/F 6)

by 180°  the clamping jaws close.

3�2�10 If available, connect the data cable (pos. 9).

Please note: Pin assignment of data cable, see page 6.

3�2�11 Check that the clamping jaws firmly grip the receptacle insert.

3�2�12 Check the connection of the filling hose end at the port ‘B2’ and of the port ‘B1’ to

the dispenser for leak tightness.

260

8.5

min.

50 mm

Figure 2

Connection Torque

UNF 9/16“-18*

internal thread

40 Nm

UNF 9/16“-18**

external thread

40 Nm

* 60° cone, MP-fitting

** 60° inner cone

Please note the marking on the

product indicating the connection

size!

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 8

D-2009/09/00712-8-3

5 ACCESSORIES | SPARE PARTS

Fittings

There are various stainless steel fittings for connecting port ‘B2’ to the filling hose available.

Please contact us!

Filling hoses

For the TSA1 H

70 MPa breakaway coupling various filling hoses for connecting fuelling nozzle

and breakaway coupling are available. Please contact us!

Spare parts

The following parts are available for product maintenance:

6 STORAGE

6�1 Protect the product against damage, dirt ingress, improper storage and excessive

temperature fluctuations.

6�2 Store the product, the accessories and spare parts in the original packaging until use.

Part No� Position Description

W92182 Pos. 4 Receptacle insert for UNF 9/16“ -18 external thread, 60° (B2)

C1-123477 Part of pos. 4 Spare seal set for receptacle insert W92182

E69-67754 Pos. 3 Wire filter insert 20 micron (incl. spring and o-ring)

In the event of accidental deployment, e.g. driving a vehicle from the dispenser with the nozzle

remaining in the vehicle fuel port, the breakaway coupling will separate the connection between

dispenser and filling hose sealing both ends.

The following points are to be observed when separation occurs:

4�1 The filling hose is to be replaced after each separation.

4�2 The fuelling nozzle is to be sent to the manufacturer for inspection.

4�3 Check the single components for damage.

4�4 The breakaway coupling is to be leak tested. If a local leak test is not possible, the break-

away coupling must also be returned to the manufacturer for inspection (see Chapter 9

- Recommissioning).

4�5 After separation check that the retaining ring and the o-ring seal are firmly positioned

in the recess of the receptacle insert (pos. 4) (see figure 1, page 7). Before reinstalling,

check the sealing components for damage.

4�6 We recommend that the receptacle in the vehicle is checked for damage and proper

function by an authorized service station.

4�7 Failure to observe these instructions invalidate warranty and liability.

4 EXAMINATION AFTER SEPARATION

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 9

D-2009/09/00712-8-3

Note the following when separation occurs or for maintenance works:

Both end connections must be depressurized prior to reassembling the breakaway coupling.

7�1 Regularly inspect the product according to the individual operating conditions, at least,

however, every 3 months. Inspect for leak tightness and correct operation (free-moving,

adequate lubrication with substances approved by WEH for this application wear, dirt

ingress, damage). The product has to be sent to the manufacturer for refurbishment after

3 years at the latest.

7�2 The filter should be serviced on a regular basis (see separate maintenance instructions,

please contact us).

7�3 WEH

Products may only be repaired or operated by the manufacturer or authorized

service personnel. If in doubt please contact us.

7�4 Only use original WEH

Spare Parts. These fit the application correctly and are subject to

strict quality control.

7�5 Violation of WEH maintenance instructions specified in this document will result in a loss

of warranty and in addition the WEH GmbH will accept no liability for consequential dama-

ge caused to persons or property.

7 MAINTENANCE

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 10

D-2009/09/00712-8-3

8 EXAMINATION OF LEAK RATE

8�1 Instructions for examination of leak rate

8�1�1 Gas detectors are not suitable to measure a technical leak rate due to the techni-

cal requirements. Therefore a gas detector can only be used as indicator. For this

reason the max. value of 1,000 ppm (see point 8.2.2) has to be regarded only as

appropriate value, not as absolute limit.

8�1�2 When using a gas detector, the min. distance of 10 cm to the components of the

breakaway coupling has to be kept.

8�1�3 We recommend to send the breakaway coupling to the manufacturer for repair,

if a value higher than 1,000 ppm is displayed. However the breakaway coupling

does not leak or is defective basically. Only when measuring with suitable

measuring devices, an exact leak rate can be determined, and on the basis of the

result, the relevance can be ascertained. We will inform you about the result of

the measurement.

8�1�4 Please note, that the sensor might display a higher value, not caused by hydro-

gen, if the hydrogen fuelling station is integrated into a liquid fuels station. In this

case, the exact background level should be determined. Indeed concentrations of

500 ppm and more have been detected. As hydrogen is significantly lighter than

air, it can be assumed, that concentrations measured below the real measuring

point, from a minimum distance of 1 m, have to be deducted from the values

measured at the H

fuelling station.

8�2 Examination of leak rate

8�2�1 We recommend to examine the leak rate once a week with a gas detector for

flammable gases.

8�2�2 If the measured leak rate exceeds 1,000 ppm, the breakaway coupling must be

removed and returned to the manufacturer for maintenance.

8�2�3 The examination of the leak rate should be effected under operating pressure

using the operating medium. Observe the relevant safety requirements imposed.

8�2�4 Measuring has to be performed at the following areas (see figure 3):

- At the fittings (1, 2)

- At the eccentric actuator (3)

- At the clamping jaws (4)

Figure 3

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 11

D-2009/09/00712-8-3

9 RECOMMISSIONING

Please note:

Ensure that both end connections are depressurized prior to reassembling the breakaway

coupling after a separation or for maintenance work.

If the system is still pressurized, the nozzle cannot be disconnected from the receptacle, nor

can the receptacle insert be reassembled to the breakaway coupling.

Therefore, please check, if the hoses are depressurized. If not, the hoses have to be vented prior

to reassembling.

Observe the safety instructions below (point 9.1) and the venting procedure (point 9.2).

9�1 Safety instructions for recommissioning

If a separation occurs during a refuelling process and pressure is locked in the hoses

between receptacle insert and fuelling nozzle, then hoses have to be vented prior to

reassembling. Please observe the following safety instructions.

9�1�1 Wear hearing protection, goggles and protective gloves during the entire process.

9�1�2 Loosen the screw connection only in well ventilated areas.

9�1�3 Keep all ignition sources away from the filling hoses during pressure venting.

9�1�4 The vent hole at the screw connection should not be hidden (see figure 4) so that

the pressure may escape unhindered. Keep the vent hole away from your body

and your face. Keep your hands or fingers away from the hole

 DANGER OF INJURY!

9�1�5 Loosen the screw connection slowly and carefully until you hear the pressure

escape. Do not loosen the screw connection too rapidly.

9�2 Venting of hoses after separation

9�2�1 Secure the receptacle insert (pos.1) by means of a spanner (figure 4) and loosen

the screw connection of the filling hose at port ‘B2’ on the breakaways’ receptacle

insert. The vent hole at the screw connection may not be hidden (figure 4).

9�2�2 Place the spanners close to each other and loosen the screw connection at the

hose as slowly and carefully as possible (see figure 5 and 6).

9�2�3 Loosen the screw connection carefully until you hear the pressure escape.

Normally a turn of 30° is sufficient for venting. Do not turn more than 90°! Should

these instructions be disregarded, the hose may jump off under pressure!

9�2�4 Once the connection is loosened, move away from the hoses until the system is

completely depressurized.

The whole venting process can last for several minutes depending on the pressure

still locked.

9�2�5 After complete venting of the hoses, remount the screw connection of the filling

hose to port ‘B2’ on the breakaways’ receptacle insert.

Please see Chapter 3 - Installation (torques, etc.)

Figure 6

Figure 5

Loosen by 30°!

Figure 4

Vent hole

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 12

D-2009/09/00712-8-3

9�3 Recommissioning

Note the following when separation occurs or for maintenance work:

Both end connections must be depressurized prior to reassembling the breakaway coupling.

9�3�1 Turn the eccentric actuator (pos. 2) by 180°  the clamping jaws open.

9�3�2 Insert the receptacle insert (pos. 4) into the breakaway coupling body (pos. 1).

9�3�3 Turn the eccentric actuator (pos. 2) again by 180°  the clamping jaws grip the

receptacle insert.

9�3�4 Check that the clamping jaws firmly grip the receptacle insert.

9�3�5 Check the connection of the filling hose end at the port ‘B2’ and of the port ‘B1’ to

the dispenser for leak tightness.

3�3�6 If available, reconnect the data cable (pos. 9).

Eccentric

Actuator

Eccentric

Actuator

180°

coupled position open position

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 13

D-2009/09/00712-8-3

10 DIMENSIONS

WEH

TSA1 H

70 MPa Breakaway Coupling

approx. dimensions (mm)

Description

Pressure

(PN)

(internal thread)

(external thread)

TSA1 H

70 MPa

with filter (20 micron)

700 bar UNF 9/16“-18* UNF 9/16“-18**

* 60° cone, MP-fitting

** 60° inner cone

415

224

296

560

Operating instructions Date: 08/2019

Type TSA1 H

70 MPa

Page 14

D-2009/09/00712-8-3

Type

PN*

(bar)

PS*

(bar)

PT*

(bar)

TSA1 H

70 MPa 700 875 1255

* Definition acc. to pressure equipment directive PED 2014/68/EU

PN = Nominal pressure referring to a gas temperature of 15 °C

PS = Max. operating pressure

PT = Test pressure

WEH

TSA1 H

70 MPa Breakaway Coupling for data interface

approx. dimensions (mm)

415

224

296

560

Description

Pressure

(PN)

(internal thread)

(external thread)

TSA1 H

70 MPa

with filter (20 micron)

700 bar UNF 9/16“-18* UNF 9/16“-18**

* 60° cone, MP-fitting

** 60° inner cone

For queries and further information, please do not hesitate to contact us.

» Contacting

Manufacturer:

WEH GmbH Gas Technology

Josef-Henle-Straße 1

89257 Illertissen / Germany

Phone: +49 7303 95190-0

Fax: +49 7303 95190-9999

Email: h2sales@weh.com

www.weh.com

Weh TSA1 H2 70 MPa Operating Instructions Manual

Brand: Weh

Model: TSA1 H2 70 MPa

Type: Operating Instructions Manual

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Weh TSA1 H2 70 MPa Operating Instructions Manual

Weh TSA1 H2 70 MPa Operating Instructions Manual

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