widos 4400 Working Instructions
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widos 4400 Working Instructions

Heating element butt welding machine
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WIDOS
Einsteinstr. 5
W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax
website: www.widos.de
Working Instructions
Heating Element Butt Welding Machine
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer
Translation
WIDOS 4400
Keep for further use!
Phone
++49 (0) 7152 9939 - 0
++49 (0) 7152 9939 - 40
email: info@widos.de
Kunststoffschweißtechnik

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  • Page 1 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0) 7152 9939 - 40 website: www.widos.de email: info@widos.de Kunststoffschweißtechnik Working Instructions Translation Heating Element Butt Welding Machine WIDOS 4400 Keep for further use! Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing director: Jürgen Dommer...
  • Page 2 St. Gallerstr. 93 D-09224 Grüna / Sachsen CH-9201 Gossau Phone: ++49 371 / 8 15 73 - 0 Phone: +41 (0) 79 432 5737 Fax: ++49 371 / 8 15 73 - 20 23.06.15 Working Instructions WIDOS 4400 Page 2 of 44...
  • Page 3 Due to this structure, the searched information can be easily found. WIDOS 23.06.2015 W. Dommer Söhne GmbH Einsteinstraße 5 D-71254 Ditzingen-Heimerdingen All rights reserved. Reprinting only allowed with permission of the corporation. Any changes prior to technical innovations. 23.06.15 Working Instructions WIDOS 4600 Page 3 of 44...

  • Page 4: Table Of Contents

    1.1. Usage and purpose oriented use ....................6 1.2. Safety measures........................6 1.3. Conformity ..........................6 1.4. Machine overview........................7 1.5. Designation of the product ......................7 1.5.1. Technical data ........................7 1.5.1.1. WIDOS 4400 General data..................7 1.5.1.2. Heating element......................8 1.5.1.3. Planer.........................8 1.5.1.4. Hydraulic aggregate....................9 1.5.1.5.
  • Page 5 HYDRAULIC AND ELECTRIC DIAGRAMS..............31 SPARE PARTS LIST ....................33 10.1. Basic machine .........................33 10.2. Planer............................35 10.3. Hydraulic aggregate........................37 10.4. Heating element........................40 10.5. Protection box .........................42 DECLARATION OF CONFORMITY ................44 23.06.15 Working Instructions WIDOS 4400 Page 5 of 44...

  • Page 6: Description Of The Product

    1.1. Usage and purpose oriented use The WIDOS 4400 has been designed only for heating element butt welding of pipes and fittings with a diameter range of Ø = 50 - 160 mm (standard diameters: 50 / 63 / 75 / 90 / 110 / 125 / 140 / 160 mm).

  • Page 7: Machine Overview

    The type labels are attached at the aggregate and at the basic machine. They contain the type, the serial number and the year of construction of the machine. 1.5.1. Technical data 1.5.1.1. WIDOS 4400 General data Material: PE, PP, PVDF,...

  • Page 8: Heating Element

    4,1 A Frequency: 50 Hz ( 10 %) RPM n of planer: 100 rpm Attached elements: - Switch on/off with fixing device - Connecting cable and plug Weight: appr. 7,5 kg 23.06.15 Working Instructions WIDOS 4400 Page 8 of 44...

  • Page 9: Hydraulic Aggregate

    Allen key angulate size 3 / 5 / 6 1 each Allen key with T grip size 3 / 4 option Reduction inserts (large, extra large), roller brackets for the pipes, transformer 23.06.15 Working Instructions WIDOS 4400 Page 9 of 44...

  • Page 10: Safety Rules

    T h e r e g u l a t i o n s f o r t h e p r e v e n t i o n o f a c c i d e n t s a r e v a l i d ( U V V ) . 23.06.15 Working Instructions WIDOS 4400 Page 10 of 44...

  • Page 11: Obligations Of The Owner

    A person who is being trained may only work at the machine under supervision of an experienced person. 23.06.15 Working Instructions WIDOS 4400 Page 11 of 44...

  • Page 12: Dangers While Handling The Machine

    Kunststoffschweißtechnik 2.7. Dangers while handling the machine The machine WIDOS 4400 is constructed according to the latest technical standard and the acknowledged technical safety rules. However, dangers for the operator or other persons standing nearby may occur. Also damages to the machine itself or to other things are possible.

  • Page 13: Specific Dangers

    Do not stand or put hands between clamped pipe ends. Do not stand or put hands between the inner clamping tools with not yet clamped pipes. Do not block opening and closing of the machine slides. 23.06.15 Working Instructions WIDOS 4400 Page 13 of 44...

  • Page 14: Structural Modifications On The Machine

    Machine parts which are not in a perfect condition are to be replaced immediately. Only use original WIDOS spare and wear parts. In case of purchase orders please always state the machine number. 2.12. Cleaning the machine...

  • Page 15: Functional Description

    The pipes are joined under prescribed welding pressure and then cool down under pressure (cooling time). The welded joint can be unclamped, the welding process is finished. Heating element heats the pipes up to welding temperature Finished welding with internal and external bead 23.06.15 Working Instructions WIDOS 4400 Page 15 of 44...

  • Page 16: Operating And Indicating Elements

    Hydraulic connection for - Non-dropping quick-acting coupling closing the slides Hydraulic connection for - Non-dropping quick-acting coupling opening the slides Screw with oil dipstick - checking the oil level - oil filler neck 23.06.15 Working Instructions WIDOS 4400 Page 16 of 44...

  • Page 17: Elements On The Side Of The Aggregate

    4.2. Elements on the side of the aggregate No. Denomination Function Socket 230V/50 Hz Possibility for connecting the planer / heating element Socket 230V/50 Hz Possibility for connecting the planer / heating element Mains cable 230V/50Hz Power supply 23.06.15 Working Instructions WIDOS 4400 Page 17 of 44...

  • Page 18: Elements At Planer And Heating Element

    It has not yet reached the desired temperature 23.06.15 Working Instructions WIDOS 4400 Page 18 of 44...

  • Page 19: Starting And Operating

    If the surrounding temperature is under 5 °C / 41 °F, measures have to be taken: Use a welding tent or preheat the pipe ends if necessary. In addition, take measures against rain, wind and dust. 23.06.15 Working Instructions WIDOS 4400 Page 19 of 44...

  • Page 20: Replacing The Reduction Inserts

    When fittings are to be welded (bends, T-pieces etc.), the inner small reduction insert can also be used flush to the inside or to the outside. Small reduction insert, centered (for pipes) Shown here: Small reduction insert, flush to the inside (for bends, T-pieces) 23.06.15 Working Instructions WIDOS 4400 Page 20 of 44...

  • Page 21: Welding Process

    Lay the pipes to be welded into the clamping devices, tighten firmly the clamping nuts and align the pipes with respect to one another. In case of long pipe ends, use WIDOS rollerstands for alignment. Close the slides, valve lever on: “FORWARDS”, thereby reading the movement pressure on the manometer.
  • Page 22 After expiration of the cooling time, release pressure, valve lever to position “Pressure release“. Open the clamping devices and remove the welded part. Open the slides, valve lever on: “BACKWARDS”. 23.06.15 Working Instructions WIDOS 4400 Page 22 of 44...

  • Page 23: Welding Log And Tables

    Einsteinstr. 5 Phone ++49 (0) 7152 9939 - 0 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0) 7152 9939 - 40 website: www.widos.de email: info@widos.de Kunststoffschweißtechnik 6. Welding log and tables 23.06.15 Working Instructions WIDOS 4400 Page 23 of 44...
  • Page 24 Welding Log and Tables Chapter 6 Kunststoffschweißtechnik 23.06.15 Working Instructions WIDOS 4400 Page 24 of 44...
  • Page 25 [bar] min. over welding [bar] time [mm] [mm] [mm] time pressure [min] 33,0 26,0 21,0 17,6 17,0 13,6 11,0 41,0 33,0 26,0 21,0 17,6 17,0 13,6 11,0 23.06.2015 Working instructions WIDOS 4400 Page 25 of 44...
  • Page 26 [bar] min. over welding [bar] time [mm] [mm] [mm] time pressure [min] 41,0 33,0 26,0 21,0 17,6 17,0 13,6 11,0 10,3 41,0 33,0 26,0 21,0 17,6 17,0 13,6 11,0 10,1 12,3 23.06.2015 Working instructions WIDOS 4400 Page 25 of 44...
  • Page 27 [bar] time [mm] [mm] [mm] time pressure [min] 41,0 33,0 26,0 21,0 17,6 17,0 13,6 10,0 11,0 12,3 15,1 41,0 33,0 26,0 21,0 17,6 17,0 13,6 11,4 11,0 14,0 17,1 23.06.2015 Working instructions WIDOS 4400 Page 25 of 44...
  • Page 28 • no additional pressure during further cooling down • load onto the workpieces only after being completely cooled down • Join parts with wall thickness 15 mm 23.06.2015 Working instructions WIDOS 4400 Page 25 of 44...
  • Page 29 [bar] min. over welding [bar] time [mm] [mm] [mm] time pressure [min] 17,6 17,6 10,5 17,6 10,3 12,5 17,6 12,3 15,0 23.06.2015 Working instructions WIDOS 4400 Page 26 / 1 of 44...
  • Page 30 [bar] min. over welding [bar] time [mm] [mm] [mm] time pressure [min] 17,6 10,0 15,1 18,3 17,6 11,4 17,1 20,8 17,6 12,7 19,2 23,3 23.06.2015 Working instructions WIDOS 4400 Page 26 / 2 of 44...
  • Page 31 • no additional pressure during further cooling down • load onto the workpieces only after being completely cooled down • Join parts with wall thickness 15 mm 23.06.2015 Working instructions WIDOS 4400 Page 26 / 3 of 44...
  • Page 32 [bar] min. over welding [bar] time [mm] [mm] [mm] time pressure [min] 10,0 10,0 11,0 23.06.2015 Working instructions WIDOS 4400 Page 27 / 1 of 44...
  • Page 33 Field 6 W4400 Double Containment Butt Fusion PIPE INITIAL MELT HEATSOAK CHANGE WELDING COOLING SIZE MELT PRESSURE TIME OVER PRESSURE TIME PRESSURE TIME (INCHES) (PSI) (SEC) (SEC) (PSI) (MIN) PP SDR11 X 33 2 x 4 (128) Almost (128) 3 x 6 17.8 (261) Zero...

  • Page 34: Maintenance And Repair

    The DVS gives the advice of inspection works after 1 year. For machines with a specially high usage percentage the testing cycle should be shortened. The works should be performed at the WIDOS GmbH company or by an authorized partner. 7.2. Clamping elements For a long service life clean and grease regularly the threaded spindles and the joint parts which are used for clamping the pipes.

  • Page 35: Checking The Hydraulic Oil-Level

    The lower vent screws always have to be vented at first because there is a direct connection between the upper and the lower cylinders. If air remains in the lower cylinder, it will ascend in the upper cylinder when pressure is applied. 23.06.15 Working Instructions WIDOS 4400 Page 29 of 44...

  • Page 36: Transport

    During the transport of the machine there may be cold weldings between the piston rod and the eyes of the planer housing. These spots on the piston rod may damage the sealing. Therefore the eyes must be lubricated with PTFE-spray before each transport! 23.06.15 Working Instructions WIDOS 4400 Page 30 of 44...

  • Page 37: Hydraulic And Electric Diagrams

    ++49 (0) 7152 9939 - 0 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen Fax ++49 (0) 7152 9939 - 40 website: www.widos.de email: info@widos.de Kunststoffschweißtechnik 9. Hydraulic and electric diagrams Working direction Hydraulic diagramm 23.06.15 Working Instructions WIDOS 4400 Page 31 of 44...
  • Page 38 Wiring Diagrams Chapter 9 Kunststoffschweißtechnik 23.06.15 Working Instructions WIDOS 4400 Page 32 of 44...

  • Page 39: Spare Parts List

    10. Spare parts list 10.1. Basic machine 14 - 15 16 - 18 9 - 10 32 - 33 20 - 21 35 - 37 23 - 25 27 - 30 40 - 41 23.06.15 Working Instructions WIDOS 4400 Page 33 of 44...
  • Page 40 Spare parts list Chapter 10 Kunststoffschweißtechnik Basic Machine WIDOS 4400 Pos. Name Piece Order no. Clamping ring upper part 160105 Outer clamping ring lower part, movable 160104 Inner clamping ring lower part, movable 160103 Inner clamping ring lower part, fixed...
  • Page 41 Spare parts list Chapter 10 Kunststoffschweißtechnik Basic Machine WIDOS 4400 Pos. Name Piece Order no. Washer M6 DIN 125 0125F Reducer inserts OD 50 - OD 140 mm 1 set 1608...* Reducer inserts large OD 50 - OD 140 mm 1 set 1618...*...

  • Page 42: Planer

    Chapter 10 Kunststoffschweißtechnik 10.2. Planer 1 / 2 31 - 35 5 - 7 36 - 39 8 - 13 16 / 17 18 - 20 21 / 22 23 - 25 23.06.15 Working Instructions WIDOS 4400 Page 35 of 44...
  • Page 43 Ball bearing L6000Z Sheet metal screw M 4,8x8 DIN 7981 7981E080 Washer M 10 DIN 125 0125J Hexagon nut M 10 DIN 934 0934J Holder for planer 160401 Planer disc, left-hand 160403 23.06.2015 Working instruction WIDOS 4400 Page 36 of 44...

  • Page 44: Hydraulic Aggregate

    Spare parts list Chapter 10 Kunststoffschweißtechnik 10.3. Hydraulic aggregate 1 - 2 4- 6 22 - 23 9 - 16 12 - 18 31 - 32 28 - 29 23.06.15 Working Instructions WIDOS 4400 Page 37 of 44...
  • Page 45 Spare parts list Chapter 10 Kunststoffschweißtechnik 44 - 48 36 - 40 54 - 55 56 - 59 51 - 52 23.06.15 Working Instructions WIDOS 4400 Page 38 of 44...
  • Page 46 Spare parts list Chapter 10 Kunststoffschweißtechnik Hydraulic Aggregate WIDOS 4400 Pos. Name Piece Order no. Protective mounting 101042 Pan-head screw M6x16 DIN 912 0912F016 Cover 1010021 Control knob for pressure setting 101022 Bush 101047 Set screw 101050 Oil dipstick 101021...
  • Page 47 Spare parts list Chapter 10 Kunststoffschweißtechnik Hydraulic Aggregate WIDOS 4400 Pos. Name Piece Order no. Set screw on request Plug-in element P83-1/2"x3/16" 101043 Pan-head tapping screw 3.5 x 20 7971C020 Side part 1010022 Screwed connection PG 13.5 EV0113 Hexagon nut M 20x1,5 brass...

  • Page 48: Heating Element

    Spare parts list Chapter 10 Kunststoffschweißtechnik 10.4. Heating element 17-19 4 / 5 21 - 23 7 / 8 10-12 13 - 16 25 - 28 23.06.15 Working Instructions WIDOS 4400 Page 40 of 44...
  • Page 49 Spare parts list Chapter 10 Kunststoffschweißtechnik Heating Element WIDOS 4400 Pos. Name Piece Order-no. Heating element H4400E Heating plate HG 205 E 230 V HP4400E Heating plate in exchange HPT4400 Tapped bushing HGEW-M6 Thermal insulating board H0902 Pan-head screw M6x75 DIN 912...

  • Page 50: Protection Box

    Spare parts list Chapter 10 Kunststoffschweißtechnik 10.5. Protection box 3 - 4 10 - 11 23.06.2015 Working Instructions WIDOS 4400 Page 42 of 44...
  • Page 51 Spare parts list Chapter 10 Kunststoffschweißtechnik Protection Box WIDOS 4400 man Pos. Name Piece Order-no. Strirrup 160537 Spacing bolt for planer 160534 Hexagon domed cap nut M8 DIN 1587 1587H Washer M8 DIN 125 0125H Spacing disc for stirrup 160536...

  • Page 52: Declaration Of Conformity

    The technical documentation is completely available. The following technical documentation can be examined at the corporation mentioned above: - testing documents - other technical documents Ditzingen-Heimerdingen, the 23.06.15 Martin Dommer (Technical director) 23.06.15 Working Instructions WIDOS 4400 Page 44 of 44...

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