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Kunststoffschweißtechnik

WIDOS

Einsteinstr. 5

Phone +49 (0) 71 52 99 39 - 0

W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen

Fax

+49 (0) 71 52 99 39 - 40

Website: www.widos.de

Email: [email protected]

20.08.2014 Working

instructions

WIDOS 4000 WM

Page 7 of 68

1. Description

of

product

This chapter gives important basic information about the product and its prescribed use.
All technical details of the machine are put together as a general arrangement.

1.1. Usage and purpose-oriented use

The

WIDOS

4000 WM

is a workshop machine for heating element butt welding of pipes and

fittings Ø = 63 – 315 mm.
(Standard-



: 63 / 75 / 90 / 110 / 125 / 140 / 160 / 180 / 200 / 225 / 250 / 280 / 315 mm).

The machine is screwed tightly on a steel pipes frame in the right working height and has two
movable machine parts (floatingly supported) with two clamping tools.
For the balance of diameter tolerances the right table half is diagonally movable to the work
direction.
For the production of segment bends 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 pressure
ratings may also be clamped and welded.

All use going beyond is not prescribed.
The manufacturer is not responsible for damages caused by misuse.
The risk is held only by the user.

Also part of the appropriate usage are



following all indications of the working instructions and



performing the inspection and maintenance works.

1.2. Safety

measures

In case of wrong use, wrong operation or wrong maintenance, the machine itself or products
standing nearby may be damaged or destroyed.
Persons who stay in the danger area may suffer injuries.
Therefore the working instructions on hand are to be red thoroughly and the corresponding
safety instructions are to be observed by all means.

1.3. Conformity

The machine corresponds in its construction to the valid recommendations of the European
Community as well as to the according European standard specifications.
The development, manufacturing and mounting of the machine were made very carefully.

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Содержание 4000 WM

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

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

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

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

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

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

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

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

Страница 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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