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widos 5000 WM, Working Instructions

The WIDOS 5000 WM is a cutting-edge welding machine with advanced features for precise and efficient welds. Ensure proper operation by following the detailed Working Instructions in the user manual. Download the free manual from manualshive.com to get the most out of your equipment.

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23.06.2015 

Working instructions WIDOS  5000 WM 

Page 6 of 80 

8.6.

 

Service unit....................................................................................................................................................51

 

8.7.

 

Protect machine parts against corrosion....................................................................................................51

 

8.8.

 

Disposal .........................................................................................................................................................51

 

9.

 

ELECTRIC, HYDRAULIC AND PNEUMATIC DIAGRAMS ....................................................................... 52

 

10.

 

DECLARATION OF CONFORMITY ...................................................................................................... 80

 

 

Summary of Contents for 5000 WM

Page 1: ...e www widos de Email info widos de Headquarters D 71254 Ditzingen Heimerdingen Country court Stuttgart HRB 200973 Managing directors J rgen Dommer Dr Kai Dombrowski Working instructions Translation He...

Page 2: ...rial 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 S hne GmbH Einsteinstrasse 5...

Page 3: ...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 us about...

Page 4: ...handling the machine 13 2 8 Dangers by electrical energy 13 2 9 Dangers by pneumatic and hydraulic 13 2 10 Specific dangers 13 2 10 1 Danger of combustion by heating element and welding area 13 2 10...

Page 5: ...element temperature 30 5 4 Welding process 30 5 4 1 How to clamp the pipes 31 5 4 2 Drag pressure measurement 31 5 4 3 How to plane the pipes 31 5 4 4 Mismatch compensation 32 5 4 5 Adjusting 32 5 4...

Page 6: ...2015 Working instructions WIDOS 5000 WM Page 6 of 80 8 6 Service unit 51 8 7 Protect machine parts against corrosion 51 8 8 Disposal 51 9 ELECTRIC HYDRAULIC AND PNEUMATIC DIAGRAMS 52 10 DECLARATION OF...

Page 7: ...ols are movable to 15 each The machine can weld T pieces with optional T clamping tools 45 60 90 with OD 500 mm By means of an optional additional cylinder huge diameters with high nominal pressure ra...

Page 8: ...r 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 generated Environmental conditions in t...

Page 9: ...te Power 1 8 kW Voltage 400 V 10 Amperage 3 5 A Frequency 50 Hz Phase shift appr 18 Hydraulic oil tank appr 1 L Type of protection IP 55 Electric motor and pump Engine revolution 1410 U min max workin...

Page 10: ...Accessories The following tools and accessories is part of the original delivery Pieces Name 1 Screwdriver TX10 1 Key for switch cupboard Attention Hand over the key to authorized personnel only each...

Page 11: ...nces for the health This symbol means a general possible dangerous situation The disrespect of these indications may cause slight injuries or damages on goods This symbol means a possible dangerous si...

Page 12: ...f 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 precautions The workin...

Page 13: ...o be consulted who disconnects the current supply if necessary Protect the heating element and planer from rain and dropping water 2 9 Dangers by pneumatic and hydraulic System sections which have to...

Page 14: ...riving in and out heating element and planer when no part of the body or object is in the way Only close clamping tools when no part of the body is between clamping tool and pipe resp between upper an...

Page 15: ...ty and Liability 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 da...

Page 16: ...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 height the...

Page 17: ...element 3 Left clamping tool for clamp the pipes 4 Hydraulic pump and tank 5 Left table with horizontal adjustment 6 Hand wheel for compensating of horizontal mismatch 7 Locking bolt for locking the p...

Page 18: ...tion of a gap during an unbalanced strain of the clamping tool Plug the pneumatic hoses of the additional cylinder to the distributer block chapter 4 1 no 16 in order to weld The additional cylinder i...

Page 19: ...nal cylinder onto the clamping tools only afterwards 4 2 Elements on the operating panel No Denomination Function 20 Pressure relief valve adjust the table pressure read value from pressure gauge 21 S...

Page 20: ...unlocked by rotating or pulling In order to return to normal operation the main switch has to be switched off and on again and the buttons Planer out and Heater out has to be pressed There is acute d...

Page 21: ...hine QM31 Planer drives into machine QM32 Planer drives out of machine The service unit LFR 3 8 D Maxi KC adjusts the incoming compressed air to the adjusted working pressure and compensates fluctuati...

Page 22: ...nel 37 Main switch for switching the machine on off 38 Mains connecting cable 400 V 32 A QA2 Emergency stop contactor FC2 Circuit breaker K8A control fuse FC10 Motor protection switch 2 8 4A hydraulic...

Page 23: ...mped with spindle pressure disc and clamping nut for this purpose swivel in or out the released spindle arrow 4 6 1 How to install the reducer inserts optional The optional reducer inserts must be flu...

Page 24: ...Pan head screw M 10 x 120DIN 912 Reduction insert OD 225 Pan head screw M 10 x 140DIN 912 Reduction insert OD 200 Pan head screw M 10 x 140DIN 912 Reduction insert OD 180 in OD 200 Flat head screw M 1...

Page 25: ...450 mm M 10 x 55 Adapter OD 315 mm Adapter OD 450 mm M 10 x 55 Reduction insert OD 280 mm Adapter OD 315 mm M 6 x 25 Reduction insert OD 160 DA 250 mm Adapter OD 315 mm M 6 x 30 You can support pipes...

Page 26: ...the clamping jaws continuously to the inside or outside Clamp the workpiece on the inside or outside with the clamping jaws according to your need In case you want to clamp a workpiece on the stub end...

Page 27: ...the clamping tool is piled on the bolt and can be swiveled to the desired welding angle Turning point scale A for angles 0 15 Turning point scale B for angles 15 22 5 Turning point scale C for T 45 2...

Page 28: ...amping tool to the left and left one to the right an angle of 30 is welded Mount the clamping tools on turning point C 4 9 3 Welding more angles In order to weld more angles you must shift clamping to...

Page 29: ...the hydraulic system therefore discharge pressure when necessary Take care that no person has to step over the lines Only skilled labors are allowed to work at electrical appliances The electrical equ...

Page 30: ...to desired value the control lamp K2 4 is on having reached the desired temperature the control lamp K2 4 is blinking 5 4 Welding process B a s i c a l l y t h e r e s p e c t i v e l y v a l i d w e...

Page 31: ...soon as the machine is starting to move with the pipes the drag pressure is shown on the pressure gauge The drag pressure must be determined properly since a too high pressure on small pipe diameters...

Page 32: ...warm up time max change over time cooling time and bead height for the pipe dimensions to be welded from the table Drive in cleaned and being at desired temperature heating element between the pipes w...

Page 33: ...tools Take out the welded pipe Close clamping tools and completely open machine tables control handle on backwards Welding is completed 5 5 How to weld angles If welding angles the welding surface of...

Page 34: ...te the sawing angle to be set corresponding to the required angle at the clamping tools or reduction inserts as follows angle of the bend sawing angle number of all welding surfaces Example 1 bend of...

Page 35: ...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 the follo...

Page 36: ...e min s s 160 4 0 41 5 0 5 40 5 5 5 5 160 4 9 33 6 1 49 5 5 6 7 160 6 2 26 7 1 62 6 6 7 9 160 7 7 21 0 8 1 5 77 6 6 8 11 160 9 1 17 6 10 1 5 91 7 7 10 13 160 9 5 17 10 1 5 95 7 7 10 13 160 11 8 13 6 1...

Page 37: ...ding 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 7 1 0 49 5 5 7 7 200...

Page 38: ...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 11 1 0 62 6 6 11 9 250 7 7 33...

Page 39: ...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 16 1 5 77 6 6 16 11 315 9 7 33 20 1...

Page 40: ...ead 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 400 9 8 41 26 1 5 98 7 7 26 13 400 12 3 33 32 2 0 123 8...

Page 41: ...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 500 12 3 41 40 2 0 123 8 8 40 16 500 15 3...

Page 42: ...11 23 16 41 180 4 4 41 4 0 5 133 5 6 4 6 180 5 5 33 5 0 5 151 5 6 5 8 180 6 9 26 6 0 5 173 6 7 6 12 180 10 2 17 6 8 1 0 220 7 10 8 17 180 16 4 11 12 1 0 298 8 15 12 26 180 24 6 7 4 17 1 5 386 11 21 17...

Page 43: ...10 C welding area 225 5 5 41 6 0 5 151 5 6 6 8 225 6 9 33 7 0 5 173 6 7 7 12 225 8 6 26 9 1 0 197 6 8 9 15 225 12 8 17 6 13 1 0 255 7 12 13 21 225 20 5 11 19 1 5 345 9 18 19 32 225 30 8 7 4 27 2 0 43...

Page 44: ...13 6 26 21 1 0 264 7 12 21 22 355 20 1 17 6 30 1 5 341 9 18 30 32 355 32 2 11 46 2 0 448 13 28 46 48 400 9 8 41 17 1 0 214 7 9 17 16 400 12 3 33 22 1 0 249 7 11 22 20 400 15 3 26 27 1 0 221 7 10 27 17...

Page 45: ...5 5 5 0 5 95 5 5 8 5 180 8 6 7 0 8 126 6 7 12 5 200 6 2 6 0 6 102 5 6 9 5 200 9 6 9 1 0 136 7 9 13 5 225 6 9 7 0 7 109 6 7 10 5 225 10 8 11 1 0 148 7 11 15 0 250 7 7 9 0 7 117 6 9 11 0 250 11 9 13 1...

Page 46: ...welding bar time mm mm mm time pressure min s s 160 4 0 41 4 0 5 40 5 5 4 5 160 4 9 33 4 1 49 5 5 4 7 160 6 2 26 5 1 62 6 6 5 9 160 7 7 21 0 6 1 5 77 6 6 6 11 160 9 1 17 6 7 1 5 91 7 7 7 13 160 9 5 17...

Page 47: ...m 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 P N...

Page 48: ...me 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 P N mm 250 6...

Page 49: ...sure 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 315 7 7 41 12...

Page 50: ...in 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 400 9 8 41 20 1 5 9...

Page 51: ...me 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 P N mm 500 12...

Page 52: ...10 19 11 34 160 26 6 6 12 2 0 405 11 23 12 41 180 4 4 41 3 0 5 133 5 6 3 6 180 5 5 33 4 0 5 151 5 6 4 8 180 6 9 26 4 0 5 173 6 7 4 12 180 10 2 17 6 6 1 0 220 7 10 6 17 180 16 4 11 9 1 0 298 8 15 9 26...

Page 53: ...wall the higher the temperature P N mm bead up heat up 225 5 5 41 5 0 5 151 5 6 5 8 225 6 9 33 6 0 5 173 6 7 6 12 225 8 6 26 7 1 0 197 6 8 7 15 225 12 8 17 6 10 1 0 255 7 12 10 21 225 20 5 11 15 1 5...

Page 54: ...10 9 33 13 1 0 230 7 10 13 18 355 13 6 26 16 1 0 264 7 12 16 22 355 20 1 17 6 23 1 5 341 9 18 23 32 355 32 2 11 35 2 0 448 13 28 35 48 400 9 8 41 13 1 0 214 7 9 13 16 400 12 3 33 16 1 0 249 7 11 16 20...

Page 55: ...5 3 8 0 160 7 7 4 0 7 117 6 4 11 0 180 5 5 4 0 5 95 5 4 8 5 180 8 6 5 0 8 126 6 5 12 5 200 6 2 5 0 6 102 5 5 9 5 200 9 6 7 1 0 136 7 7 13 5 225 6 9 6 0 7 109 6 6 10 5 225 10 8 8 1 0 148 7 8 15 0 250 7...

Page 56: ...www widos de Email info widos de 23 06 2015 Working instructions WIDOS 5000 WM Page 42 of 80 7 Welding 90 45 60 T The welding process is in almost the same manner as the welding process for straight p...

Page 57: ...Welding 90 45 60 T piece Chapter 7 23 06 2015 Working instructions WIDOS 5000 WM Page 43 of 80...

Page 58: ...First welding The prepared pipes are welded in both clamping tools in the front Second welding for T piece 90 The welded pipe is clamped in both clamping tools on the left The third prepared pipe is...

Page 59: ...ng instructions WIDOS 5000 WM Page 45 of 80 7 3 Clamping tools for T piece 45 First welding The prepared pipes are welded in both clamping tools in the front Front view Cut from above fixing holes mar...

Page 60: ...e 46 of 80 Second welding for T piece 45 Front view Cut from above fixing holes marked in black Left table fixing holes marked on machine table Right table center of rotation C marked for left clampin...

Page 61: ...hapter 7 23 06 2015 Working instructions WIDOS 5000 WM Page 47 of 80 7 4 Clamping tools for T piece 60 Second welding for T piece 45 Front view Cut from above fixing holes marked in black Fixing holes...

Page 62: ...e 48 of 80 Second welding for T piece 60 Front view Cut from above fixing holes marked in black Left table fixing holes marked on machine table Right table center of rotation D marked for left clampin...

Page 63: ...itching 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 percentage the t...

Page 64: ...en the machine is switched off Remove cover on the heating element side In case the chain is too loose release the chain tensioning bolt and shift it slightly within the oblong hole until the chain is...

Page 65: ...below to let off the condensating water With less flow despite same pressure setting Replace the filter element Ventilate system and unit Unscrew the filter bowl in an anti clockwise direction Hold n...

Page 66: ...2 99 39 0 Wilhelm Dommer S hne D 71254 Ditzingen Heimerdingen Fax 49 0 71 52 99 39 40 GmbH Website www widos de Email info widos de 23 06 2015 Working instructions WIDOS 5000 WM Page 52 of 80 9 Electr...

Page 67: ...Electric hydraulic and pneumatic diagrams Chapter 9 23 06 2015 Working instructions WIDOS 5000 WM Page 53 of 80...

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Page 94: ...0 WM to which this declaration refers to corresponds to the following norms and normative documents 1 DIN EN ISO 12100 1 and 2 substitute for DIN EN 292 Part 1 and 2 Safety of machines basic terminolo...

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