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widos 4000 WM, Working Instructions Translation

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Kunststoffschweißtechnik

Product identification 

20.08.2014 Working 

instructions 

WIDOS  4000 WM 

Page 2 of 68 

Model: 

Workshop machine 

Type: 

WIDOS  4000 WM 

Serial number, year of construction: 

see type label 

 

Customer entries 

 

Inventory-No.: 

 

Location: 

 

 
 

Order of spare parts and sales services 

 
 

Address of manufacturer

 

WIDOS 
Wilhelm Dommer Söhne GmbH 
Einsteinstrasse 5 

D-71254  Ditzingen-Heimerdingen 

Phone:   +49 (0) 71 52 / 99 39 - 0 
Fax:  

+49 (0) 71 52 / 99 39 - 40 

 
 

 
Address of the subsidiary companies: 
 
 

WIDOS 

WIDOS GmbH 

 

Wilhelm Dommer Söhne AG 

An der Wiesenmühle 15   

St. Gallerstr. 93 

D-09224  Grüna / Sachsen 

CH-9201  Gossau 

Phone:  ++49 371 / 8 15 73 - 0 

Phone:   +41 (0) 79  432 57 37 

Fax: 

++49 371 / 8 15 73 - 20 

 
 

Summary of Contents for 4000 WM

Page 1: ...52 99 39 40 Website www widos de Email info widos de Headquarters D 71254 Ditzingen Heimerdingen Country court Stuttgart HRB 200973 Managing director J rgen Dommer Working instructions Translation Hea...

Page 2: ...No Location Order of spare parts and sales services Address of manufacturer WIDOS Wilhelm Dommer S hne GmbH Einsteinstrasse 5 D 71254 Ditzingen Heimerdingen Phone 49 0 71 52 99 39 0 Fax 49 0 71 52 99...

Page 3: ...visers in the factory or in our subsidiary companies We will help you with pleasure According to our interest to continuously improve our products and working instructions we kindly ask you to inform...

Page 4: ...ik WIDOS Einsteinstr 5 Phone 49 0 71 52 99 39 0 W Dommer S hne GmbH D 71254 Ditzingen Heimerdingen Fax 49 0 71 52 99 39 40 Website www widos de Email info widos de 20 08 2014 Working instructions WIDO...

Page 5: ...tructions for the staff 14 2 7 Dangers while handling the machine 15 2 8 Dangers by electrical energy 15 2 9 Dangers by hydraulic 15 2 10 Specific dangers 15 2 10 1 Danger of combustion by heating ele...

Page 6: ...clamp the pipes 35 5 3 2 Drag pressure measurement 35 5 3 3 How to plane the pipes 35 5 3 4 Mismatch compensation 36 5 3 5 Adjusting 36 5 3 6 Heating up 37 5 3 7 Change over 37 5 3 8 Joining 37 5 4 Ho...

Page 7: ...s both clamping tools can be moved The machine can weld T pieces with optional T clamping tools 45 60 90 with OD 315 mm By means of an optional additional cylinder huge diameters with high nominal pre...

Page 8: ...planing it is obligatory to wear ear protection In case of use of the prescribed plastic materials and if the work is performed inside the temperature range up to 260 C no toxic fumes will be generate...

Page 9: ...eed planer disc 50 70 rpm 1 4 1 5 Hydraulic aggregate Power 0 75 kW Voltage 400 V 10 Amperage 1 69 A Frequency 50 Hz Hydraulic oil tank appr 1 L Type of protection IP 55 Electric motor and pump Engine...

Page 10: ...mm Flat head screw M 10 x 140 DIN 7991 4 4 Reduction insert OD 75 in OD 90 mm Flat head screw M 10 x 140 DIN 7991 4 4 Reduction insert OD 90 in OD 110 mm Flat head screw M 10 x 130 DIN 7991 4 4 Reduct...

Page 11: ...d screw M 10 x 60 DIN 7991 1 set 12 T reduction insert DA 250 in DA 280 mm Flat head screw M 10 x 45 DIN 7991 1 set 12 T reduction insert OD 280 in OD 315 mm Flat head screw M 10 x 45 DIN 7991 2 T 45...

Page 12: ...k WIDOS Einsteinstr 5 Phone 49 0 71 52 99 39 0 W Dommer S hne GmbH D 71254 Ditzingen Heimerdingen Fax 49 0 71 52 99 39 40 Website www widos de Email info widos de 20 08 2014 Working instructions WIDOS...

Page 13: ...have heavy consequences for the health This symbol means a possible dangerous situation The disrespect of these indications may cause slight injuries or damages on goods This symbol means a possible d...

Page 14: ...4 Measure of organization All equipment required for personal safety is to be provided by the owner All available safety equipment is to be inspected regularly 2 5 Information about safety precaution...

Page 15: ...to be consulted who disconnects the current supply if necessary Protect the heating element and planer from rain and dropping water 2 9 Dangers by hydraulic System sections which have to be opened in...

Page 16: ...part 2 10 3 Danger of cutting and drawing in of clothes by the planer You can carry away cut injuries up to fractures Do wear formfitting clothes Do not wear any rings or jewelry during work If necess...

Page 17: ...Our General Sales and Delivery Conditions are principally valid They are at the owner s disposal at the latest when signing the contract Warranty and liability demands referring to damages of persons...

Page 18: ...k WIDOS Einsteinstr 5 Phone 49 0 71 52 99 39 0 W Dommer S hne GmbH D 71254 Ditzingen Heimerdingen Fax 49 0 71 52 99 39 40 Website www widos de Email info widos de 20 08 2014 Working instructions WIDOS...

Page 19: ...ecked Then the heating element is driven inside and the pipes are pressed onto the heating element under the defined pressure this process is called adjustment time After reaching the prescribed bead...

Page 20: ...k WIDOS Einsteinstr 5 Phone 49 0 71 52 99 39 0 W Dommer S hne GmbH D 71254 Ditzingen Heimerdingen Fax 49 0 71 52 99 39 40 Website www widos de Email info widos de 20 08 2014 Working instructions WIDOS...

Page 21: ...ends 3 Locking for planer 4 Left clamping tool 5 Left table 6 Button for cutting pipe ends 7 Main switch for switching machine on off 8 Button for closing tables 9 Button for opening tables 10 Switch...

Page 22: ...The right machine table has a horizontal adjustment in order to compensate the mismatch of the pipes arrow Detach the four pan head screws on the table Shift the table manually in arrow direction unt...

Page 23: ...Display DESIRED temperature blinking points between the numbers The heating element is being heated up the desired temperature is not yet reached This display disappears after short time followed by...

Page 24: ...the planer must always be locked in the front of the machine For lifting and lowering the locking bolt push the lever to the right side For locking pull the lever to the front If the planer is in init...

Page 25: ...30 V FC10 Motor protective switch 1 8 2 5 A hydraulic pump QA10 Contactor hydraulic pump QA40 Contactor planer 4 7 Clamping tools with 15 Insert the pipe into the lower clamping tool and put the upper...

Page 26: ...achine center Then put all further reductions over until you have the right size After having inserted the last reducer insert fix the reducers with the flat head screw Mount the reducers into all low...

Page 27: ...the desired angle you can read the angle from the scale Screw the tool onto the centering bolt with the hexagon socket nut and fix the tool additionally with two clamping jaws Illustration left table...

Page 28: ...straight pipes Illustration of machine tables view from above For a straight welding mount the clamping tools into the drill holes no 3 drill holes are marked Sectional view through clamping tool foot...

Page 29: ...th clamping tools 15 right clamping tool to the left and left one to the right an angle of 30 is welded For a 30 welding mount the clamping tools into the drill holes no 1 drill holes are marked Secti...

Page 30: ...15 the right clamping tool to the left and left one to the right and by additional interchanging an angle of 45 is welded For a 45 welding mount the clamping tools into the drill holes no 2 drill hol...

Page 31: ...ipes You must remove the cylinder and put it on its optinal holder at the left side after welding and before you open the clamping tools There is risk of injury by the additional cylinder If the conne...

Page 32: ...enter of the stub end holder Tighten the hexagon socket screws thus clamping the cap flange Clamp the pipe into the other clamping tool Drive the clamped workpieces together and align the cap flange t...

Page 33: ...d laborers are allowed to work at electrical appliances The electrical equipment of the machine has to be checked regularly Loose connections and damaged cables have to be replaced immediately If work...

Page 34: ...ed in the working area Do wear safety gloves as protection against burning Clean the heating element only in cold condition danger of inflammation caused by cleaning agents Make sure that nobody can t...

Page 35: ...tional cylinder onto the clamping tools chapter 4 8 Drive the tables slightly together again with button and read the motion pressure from the pressure gauge As soon as the machine is starting to move...

Page 36: ...ly align the pipes via the right machine table chapter 4 2 resp you can compensate the pipes by changing the clamping As soon as a mismatch compensation is effected the pipes have to be planed again A...

Page 37: ...hock free together with the cooling pressure via button until the pressure is displayed at the pressure gauge Turn the pressure relief valve until the added pressure is shown on the pressure gauge coo...

Page 38: ...02 Welding 30 chamfered pipe with 15 1 04 Welding 45 chamfered pipe with 22 5 1 08 Welding 60 chamfered pipe with 30 1 15 Welding 90 T chamfered pipe with 45 1 41 Welding 60 T chamfered pipe with 60...

Page 39: ...ings with additional cylinder page 39 41 6 1 Formulas for the welding of pipes with different diameters The aligning pressure welding pressure can be calculated for all pipes with special measures by...

Page 40: ...lding bar time mm mm mm time pressure min s s 63 1 8 41 0 1 0 5 20 4 4 1 2 63 2 0 33 0 2 0 5 20 4 4 2 2 63 2 5 26 0 2 0 5 25 4 4 2 3 63 3 0 21 0 2 0 5 30 4 4 2 4 63 3 6 17 6 2 0 5 36 5 5 2 5 63 3 8 17...

Page 41: ...me mm mm mm time pressure min s s in welding area Table for PE bead up heat up Additional to the given bead up force and to the welding force the moving force of the support must be added welding area...

Page 42: ...ssure min s s in welding area Table for PE bead up heat up Additional to the given bead up force and to the welding force the moving force of the support must be added welding area P N mm 125 3 1 41 0...

Page 43: ...min s s in welding area Table for PE bead up heat up Additional to the given bead up force and to the welding force the moving force of the support must be added welding area P N mm 160 4 0 41 0 6 0 5...

Page 44: ...s in welding area Table for PE bead up heat up Additional to the given bead up force and to the welding force the moving force of the support must be added welding area P N mm 200 4 9 41 9 1 0 49 5 5...

Page 45: ...elding area Table for PE bead up heat up Additional to the given bead up force and to the welding force the moving force of the support must be added welding area P N mm 250 6 2 41 13 1 0 62 6 6 13 9...

Page 46: ...s in welding area Table for PE bead up heat up Additional to the given bead up force and to the welding force the moving force of the support must be added welding area P N mm 315 7 7 41 21 1 5 77 6...

Page 47: ...3 10 5 6 4 1 0 224 7 10 4 18 75 1 9 41 1 0 5 90 4 5 1 2 75 2 3 33 1 0 5 95 4 5 1 2 75 2 9 26 2 0 5 106 4 5 2 3 75 4 3 17 6 2 0 5 131 5 6 2 6 75 6 8 11 3 0 5 172 6 7 3 12 75 10 3 7 4 4 1 0 221 7 10 4 1...

Page 48: ...F welding area in welding area The smaller the pipe wall the higher the temperature P N mm bead up heat up 110 2 7 41 2 0 5 103 4 5 2 3 110 3 4 33 3 0 5 115 5 6 3 4 110 4 2 26 3 0 5 130 5 6 3 6 110 6...

Page 49: ...ea in welding area The smaller the pipe wall the higher the temperature P N mm bead up heat up 160 4 0 41 4 0 5 126 5 6 4 5 160 4 9 33 5 0 5 141 5 6 5 7 160 6 2 26 6 0 5 162 6 7 6 10 160 9 1 17 6 8 1...

Page 50: ...410 F 50 F welding area in welding area The smaller the pipe wall the higher the temperature P N mm bead up heat up 225 5 5 41 7 0 5 151 5 6 7 8 225 6 9 33 9 0 5 173 6 7 9 12 225 8 6 26 11 1 0 197 6...

Page 51: ...be added The standard value for heating element temperature is 210 C 10 C 410 F 50 F welding area in welding area The smaller the pipe wall the higher the temperature P N mm bead up heat up 315 7 7 41...

Page 52: ...06 5 4 10 0 125 3 9 3 0 5 79 4 3 6 5 125 6 0 5 0 6 100 5 5 9 0 140 4 3 4 0 5 83 4 4 7 0 140 6 7 6 0 6 107 6 6 10 0 160 4 9 5 0 5 89 5 5 8 0 160 7 7 7 0 7 117 6 7 11 0 180 5 5 6 0 5 95 5 6 8 5 180 8 6...

Page 53: ...pressure down OD s bar min s over welding bar time mm mm mm time pressure min s s 63 1 8 41 0 1 0 5 20 4 4 1 2 63 2 0 33 0 1 0 5 20 4 4 1 2 63 2 5 26 0 2 0 5 25 4 4 2 3 63 3 0 21 0 2 0 5 30 4 4 2 4 6...

Page 54: ...wn OD s bar min s over welding bar time mm mm mm time pressure min s s Table for PE Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm...

Page 55: ...over welding bar time mm mm mm time pressure min s s Table for PE Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up w...

Page 56: ...lding bar time mm mm mm time pressure min s s Table for PE Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up welding a...

Page 57: ...bar time mm mm mm time pressure min s s Table for PE Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up welding area i...

Page 58: ...e mm mm mm time pressure min s s Table for PE Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up welding area in weldin...

Page 59: ...bar time mm mm mm time pressure min s s Table for PE Additional to the given bead up force and to the welding force the moving force of the support must be added P N mm bead up heat up welding area in...

Page 60: ...95 4 5 1 2 75 2 9 26 1 0 5 106 4 5 1 3 75 4 3 17 6 2 0 5 131 5 6 2 6 75 6 8 11 3 0 5 172 6 7 3 12 75 10 3 7 4 4 1 0 221 7 10 4 17 75 12 5 6 4 1 0 251 7 11 4 21 90 2 2 41 1 0 5 94 4 5 1 2 90 2 8 33 2...

Page 61: ...ead up heat up welding area 125 3 1 41 2 0 5 110 4 5 2 4 125 3 9 33 3 0 5 124 5 6 3 5 125 4 8 26 3 0 5 140 5 6 3 7 125 7 1 17 6 4 1 0 176 6 7 4 12 125 11 4 11 7 1 0 237 7 11 7 19 125 17 1 7 4 9 1 0 30...

Page 62: ...area P N mm bead up heat up welding area 200 4 9 41 5 0 5 141 5 6 5 7 200 6 2 33 6 0 5 162 6 7 6 10 200 7 7 26 7 1 0 185 6 8 7 13 200 11 4 17 6 11 1 0 237 7 11 11 19 200 18 2 11 16 1 0 320 9 16 16 29...

Page 63: ...410 F 50 F The smaller the pipe wall the higher the temperature Additional to the given bead up force and to the welding force the moving force of the support must be added in welding area P N mm bea...

Page 64: ...4 2 6 0 110 5 3 3 0 5 93 5 3 8 5 110 6 6 4 0 6 106 5 4 10 0 125 3 9 3 0 5 79 4 3 6 5 125 6 0 4 0 6 100 5 4 9 0 140 4 3 3 0 5 83 4 3 7 0 140 6 7 5 0 6 107 6 5 10 0 160 4 9 4 0 5 89 5 4 8 0 160 7 7 6 0...

Page 65: ...ite www widos de Email info widos de 20 08 2014 Working instructions WIDOS 4000 WM Page 46 of 68 7 Welding T pieces with 90 and 45 The welding process is in almost the same manner as the welding proce...

Page 66: ...Kunststoffschwei technik Welding T piece with 90 and 45 Chapter 7 20 08 2014 Working instructions WIDOS 4000 WM Page 47 of 68...

Page 67: ...d welding for T piece 90 The welded pipe is clamped in both clamping tools on the left The third prepared pipe is clamped in the right clamping tool For a T 90 welding mount the large clamping tool on...

Page 68: ...larger diameters The prepared pipes are welded in both clamping tools in the front For a T 90 welding mount the clamping tool on both tables drill holes no 5 1 drill holes are marked Top view of T 45...

Page 69: ...repared pipes are welded in both clamping tools in the front For a T 90 welding mount the clamping tool on both tables drill holes no 5 2 drill holes are marked Top view of T 45 lower clamping tools f...

Page 70: ...t side Clamp the third prepared pipe into the right 15 clamping tool Left table Mount both large clamping tools onto the drill holes no 6 Right table Mount the left 15 clamping tool onto the drill hol...

Page 71: ...t unauthorized switching on Prescribed maintenance and inspection works should be performed in time The DVS gives the advice of inspection works after 1 year For machines with an especially high usage...

Page 72: ...hand tight In order to modify the chain tension shift the heating element completely to the front while the machine has been shut off Remove the cover from the planer In case the chain is too loose r...

Page 73: ...loading capacity soil bearing and limited water binding The hydraulic oil must be disposed of expertly 8 6 Protect machine parts against corrosion In case of air humidity of 85 and or high temperatur...

Page 74: ...k WIDOS Einsteinstr 5 Phone 49 0 71 52 99 39 0 W Dommer S hne GmbH D 71254 Ditzingen Heimerdingen Fax 49 0 71 52 99 39 40 Website www widos de Email info widos de 20 08 2014 Working instructions WIDOS...

Page 75: ...insteinstr 5 Phone 49 0 71 52 99 39 0 W Dommer S hne GmbH D 71254 Ditzingen Heimerdingen Fax 49 0 71 52 99 39 40 Website www widos de Email info widos de 20 08 2014 Working instructions WIDOS 4000 WM...

Page 76: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 57 of 68...

Page 77: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 58 of 68...

Page 78: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 59 of 68...

Page 79: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 60 of 68...

Page 80: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 61 of 68...

Page 81: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 62 of 68...

Page 82: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 63 of 68...

Page 83: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 64 of 68...

Page 84: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 65 of 68...

Page 85: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 66 of 68...

Page 86: ...Kunststoffschwei technik Wiring diagrams Chapter 9 20 08 2014 Working instructions WIDOS 4000 WM Page 67 of 68 Hydraulic diagram...

Page 87: ...hat the product Heating element butt welding machine WIDOS 4000 WM to which this declaration refers to corresponds to the following norms and normative documents 1 DIN EN ISO 12100 1 and 2 substitute...

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