widos 4001 Working Instructions Translation
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widos 4001 Working Instructions Translation

Heating element-butt welding machine
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WIDOS
W. Dommer Söhne GmbH
Working instructions
Heating element-butt welding machine
Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing Director: Jürgen Dommer
Einsteinstr. 5
D-71254 Ditzingen-Heimerdingen
info @ widos.de
Translation
WIDOS 4001
Keep for further use !
Phone +49 / 71 52 99 39 - 0
Fax
+49 / 71 52 99 39 - 40
www.widos.de
Kunststoffschweißtechnik

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  • Page 1 WIDOS Einsteinstr. 5 Phone +49 / 71 52 99 39 - 0 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen +49 / 71 52 99 39 - 40 info @ widos.de www.widos.de Kunststoffschweißtechnik Working instructions Translation Heating element-butt welding machine WIDOS 4001 Keep for further use ! Headquarters: D-71254 Ditzingen-Heimerdingen Country court Stuttgart HRB 200973 Managing Director: Jürgen Dommer...
  • Page 2 ++49 371 / 8 15 73 - 0 Phone: ++41 71 / 388 89 79 Fax: ++49 371 / 8 15 73 - 20 Fax: ++41 71 / 388 89 73 25.06.12 Working instructions WIDOS 4001 Page 2 of 59...
  • Page 3 Therefore the searched information can be found easily.  WIDOS 25.06.2012 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. 25.06.12 Working instructions WIDOS 4001 Page 3 of 59...

  • Page 4: Table Of Contents

    Mounting and purpose-oriented use ..................6 1.2. Safety measures........................7 1.3. Conformity ..........................7 1.4. Marking of product .......................7 1.4.1. Technical data ........................7 1.4.1.1. WIDOS 4001 general data..................7 1.4.1.2. Heating element ......................8 1.4.1.3. Planer.........................8 1.4.1.4. Hydraulic aggregate ....................8 1.4.1.5. Basic unit........................8 1.5. Equipment and accessories: ....................9 SAFETY RULES ......................
  • Page 5 Conversion kit for clamping tool..................49 9.7. Conversion kit for planer ....................51 9.8. Conversion kit for heating element...................53 9.9. Hydraulic box ........................55 9.10. Plane girder for planing only at one side .................57 DECLARATION OF CONFORMITY................. 59 25.06.12 Working instructions WIDOS 4001 Page 5 of 59...

  • Page 6: Description Of Product

    1.1. Mounting and purpose-oriented use The WIDOS 4001 is a workshop machine and especially designed for the heating element butt welding of pipes and fittings from Ø = 90 mm - 315 mm (standard diameters are 90 / 110 / 125 / 140 / 160 / 180 / 200 / 225 / 250 / 280 / 315 mm).

  • Page 7: Safety Measures

    The product is marked by a type-plate at the basic machine. It contains the machine type, the serial number and the year of construction. 1.4.1. Technical data 1.4.1.1. WIDOS 4001 general data Material: PP; PE 80; PE 100, PVDF Pipe dimension: Outside-∅...

  • Page 8: Heating Element

    Frame material: Constructin steel Cylinder-∅: 25 mm Piston rod-∅: 18 mm max.force (F=P*A) 236 N (at 100 bar) 5,9 kN (at 250 bar) Moving speed of the piston: approx. 5,6 cm/s 25.06.12 Working instructions WIDOS 4001 Page 8 of 59...

  • Page 9: Equipment And Accessories

    Plane girder for planing only at one side Screw driver with Torx drive T10 optional different reduction inserts, rollerstands as pipe support, clamping tools for fabrication of T-pieces For order numbers and single parts see spare parts list 25.06.12 Working instructions WIDOS 4001 Page 9 of 59...

  • Page 10: Safety Rules

    T h e a c c i d e n t p r e v e n t i o n m e a s u r e s a r e v a l i d ( U V V ) . 25.06.12 Working instructions WIDOS 4001 Page 10 of 59...

  • Page 11: Obligations Of The Owner

    It must be clearly defined who is responsible for transport, mounting and dismounting, and • starting the operation. A person who is being trained may only work at the machine under supervision of an • experienced person. 25.06.12 Working instructions WIDOS 4001 Page 11 of 59...

  • Page 12: Dangers While Handling The Machine

    Kunststoffschweißtechnik 2.7. Dangers while handling the machine The machine WIDOS 4001 has been constructed according to the latest standards of the technology and according to the recognized technical rules. Although, during the operation dangers for the user or for persons standing close as well as damages for items may occur.

  • Page 13: Danger Of Being Burned At The Heating Element And At The Welding Point

    • In case of working inside the machine, the mains plug always has to be switched off and secured against unauthorized activation. • During the installation of the reducer inserts use a lifting device, do not reach between reducer insert and clamping tool • Don’t hinder moving tables. 25.06.12 Working instructions WIDOS 4001 Page 13 of 59...

  • Page 14: Risk Of Injury By Noise

    • Machine parts which are not in perfect condition have to be replaced immediately. • Only use original WIDOS spare and wear parts. • In case of order, always state the machine number! 2.11. Warranty and liability Basically, our "General Terms of sale and delivery“...

  • Page 15: Description Of Process

    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 up the pipes up to welding temperature Finished welding with inside and outside bead 25.06.12 Working instructions WIDOS 4001 Page 15 of 59...

  • Page 16: Operating And Indicating Elements

    - Handcarrying the machine - can be unscrewed if need be. Planer - Planing the pipe ends to be welded. - Is switched on over the switch at the control desk. 25.06.12 Working instructions WIDOS 4001 Page 16 of 59...

  • Page 17: Elements On The Right Side

    - Limitation of the hydraulic pressure onto the desired valve value. (adjustable from 0 - 250 bar) 4.2. Elements on the right side Denomination Function Clamping lever - Loosen for moving the right table half, for horizontal mismatch compensation. 25.06.12 Working instructions WIDOS 4001 Page 17 of 59...

  • Page 18: Elements On The Heating Element

    - on: the heating element is being heated up at the moment. The desired temperature has not yet been reached. Control lamp green - Indication for mains operated Control knob - Temperature control 25.06.12 Working instructions WIDOS 4001 Page 18 of 59...

  • Page 19: Wells At The Table

    Centering bolt for front / back clamping tool / swiveling axle Angle marks for clamping tools front / back Fixing for table Fixing for clamping tool Fixing for clamping tool front back 25.06.12 Working instructions WIDOS 4001 Page 19 of 59...

  • Page 20: Starting And Operating

    (e.g. technical pure alcool) or cleaning cloths which are available at the WIDOS company. The anti-adhesive coating of the heating element should be undamaged in the working area Be sure that all hydraulic and electric connections are connected.

  • Page 21: Welding Process

    • Lay the work pieces into the clamping shells, fasten the clamping screws and align the work pieces to each other. • Use the WIDOS rollerstand for the alignment of long pipe ends, for bows use the supporting angle and pipe supports.
  • Page 22 • If required set the pressure again during cooling (the pressure for cooling is the same like the set adjusting pressure). • After completion of the cooling time release pressure, remove the welded parts and open the machine. The welding process is finished. 25.06.12 Working instructions WIDOS 4001 Page 22 of 59...
  • Page 23 90° 4 segments (6 welding surfaces) Example 1: 90° sawing angle = ----- = 15° Example 2: bend of 45° in 3 segments (4 welding surfaces) 45° sawing angle = ----- = 11,25° 25.06.12 Working instructions WIDOS 4001 Page 23 of 59...

  • Page 24: Welding Of Cross- And T-Pieces

    The optional available clamping device for angles is screwed on together with the adapter plate and standard tools. T - pieces (45°, 60° and 90°) and Cross-pieces up to OD=250 mm can be welded. 25.06.12 Working instructions WIDOS 4001 Page 24 of 59...
  • Page 25 Starting and operating Chapter 5 Kunststoffschweißtechnik 25.06.12 Working instructions WIDOS 4001 Page 25 of 59...

  • Page 26: Welding Logs And Tables

    Phone +49 / 71 52 99 39 - 0 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen +49 / 71 52 99 39 - 40 info @ widos.de http://www.widos.de Kunststoffschweißtechnik 6. Welding logs and tables 25.06.12 Working instructions WIDOS 4001 Page 26 of 59...
  • Page 27 Welding logs and tables Chapter 6 Kunststoffschweißtechnik 25.06.12 Working instructions WIDOS 4001 Page 27 of 59...
  • Page 28 Table for PE Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N PE 80 The value for heating element temperature is between 200° C - 220° C.
  • Page 29 Table for PE Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N PE 80 The value for heating element temperature is between 200° C - 220° C.
  • Page 30 Table for PE Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N PE 80 The value for heating element temperature is between 200° C - 220° C.
  • Page 31 Table for PE Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N PE 80 The value for heating element temperature is between 200° C - 220° C.
  • Page 32 Table for PE Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N PE 80 The value for heating element temperature is between 200° C - 220° C.
  • Page 33 Table for PE Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N PE 80 The value for heating element temperature is between 200° C - 220° C.
  • Page 34 Table for PE Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N PE 80 The value for heating element temperature is between 200° C - 220° C.
  • Page 35 Table for PP Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N The standard value for heating element temperature is 210° C +/- 10° C. The smaller the pipe wall the higher the temperature.
  • Page 36 Table for PP Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N The standard value for heating element temperature is 210° C +/- 10° C. The smaller the pipe wall the higher the temperature.
  • Page 37 Table for PP Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N The standard value for heating element temperature is 210° C +/- 10° C. The smaller the pipe wall the higher the temperature.
  • Page 38 Table for PP Kunststoffschweißtechnik Foundation: 2207, 2208 DIN 16932 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N The standard value for heating element temperature is 210° C +/- 10° C. The smaller the pipe wall the higher the temperature.
  • Page 39 Table for PVDF Kunststoffschweißtechnik Foundation: 2208, 2207 Part 15 German association for welding Use for: 4000 / 4001 / 4002 1 bar on manometer: 23 N The standard value for heating element temperature is 240° C +/- 8° C. The smaller the pipe wall the higher the temperature.

  • Page 40: Maintenance And Repair

    Should for machines with a specially high usage percentage the testing cycle be shortened . The works should be performed at the WIDOS GmbH company or by an authorized partner. The linear guides for heating element and planer must be cleaned every week e.g.

  • Page 41: Checking The Level Of The Hydraulic Oil

    • If need be, dismount the planer and the heating element: For that purpose remove the heating Remove the four screws (S) from the planer element from the holder (see arrow) and then the planer itself 25.06.12 Working instructions WIDOS 4001 Page 32 of 59...

  • Page 42: Venting The Hydraulic Cylinders

    At the end of their life time, the machine and the wear parts have to be disposed of properly and non-polluting, and in accordance with the national laws of waste disposal. 25.06.12 Working instructions WIDOS 4001 Page 33 of 59...

  • Page 43: Wiring And Hydraulic Diagrams

    Phone +49 / 71 52 99 39 - 0 W. Dommer Söhne GmbH D-71254 Ditzingen-Heimerdingen +49 / 71 52 99 39 - 40 info @ widos.de http://www.widos.de Kunststoffschweißtechnik 8. Wiring and hydraulic diagrams 25.06.12 Working instructions WIDOS 4001 Page 34 of 59...
  • Page 44 Wiring and hydraulic diagrams Chapter 8 Kunststoffschweißtechnik 25.06.12 Working instructions WIDOS 4001 Page 35 of 59...
  • Page 45 Wiring and hydraulic diagrams Chapter 8 Kunststoffschweißtechnik 25.06.12 Working instructions WIDOS 4001 Page 36 of 59...

  • Page 46: Spare Parts List

    @ widos.de http://www.widos.de Kunststoffschweißtechnik 9. Spare parts list 9.1. Basic machine 1 - 3 4 - 5 8 - 9 10 - 11 18 - 19 13 - 14 16 - 17 25.06.12 Working instructions WIDOS 4001 Page 37 of 59...
  • Page 47 Spare parts list Chapter 9 Kunststoffschweißtechnik 29 - 30 21 - 22 32 - 36 37 - 39 24 - 25 26 - 28 40 - 42 43 - 47 48 - 49 25.06.12 Working instructions WIDOS 4001 Page 38 of 59...
  • Page 48 Spare parts list Chapter 9 Kunststoffschweißtechnik WIDOS 4001 Basic unit Pos. Name Piece Order no. Linear guide with slide L30600TR Pan-head screw M 8x30 DIN 912 0912H030 Cap for linear guide L30601 Rear girder 023104 Rivet nut M 10 N1002...
  • Page 49 Spare parts list Chapter 9 Kunststoffschweißtechnik WIDOS 4001 Basic unit Pos. Name Piece Order no. Hexagon nut M 14 DIN 934 0934N Counter support 023117 Washer M10 DIN 9021 9021J Hexagon head screw M 10x70 DIN 933 0933J070 Slide, right...

  • Page 50: Clamping Tool

    Spare parts list Chapter 9 Kunststoffschweißtechnik 9.2. Clamping tool (23) (24) 5 - 6 8 - 9 15 - 16 17 - 18 25.06.12 Working instructions WIDOS 4001 Page 40 of 59...
  • Page 51 Spare parts list Chapter 9 Kunststoffschweißtechnik WIDOS 4001 Clamping tools Pos. Piece Order no. Center pin 020117 Supporting angle 023712 Pipe support 1 Set 0206...* Pipe support 023711 Clamping lever M 12/30° BM1230 Insert nut 023713 Guide rail 023724 Pan-head screw M 10x20 DIN 7984...

  • Page 52: Planer

    Spare parts list Chapter 9 Kunststoffschweißtechnik 9.3. Planer 1 - 3 13 - 15 4 - 7 17 - 22 23 - 24 25.06.12 Working instructions WIDOS 4001 Page 42 of 59...
  • Page 53 Spare parts list Chapter 9 Kunststoffschweißtechnik 27 - 31 34 - 35 38 - 40 25.06.12 Working instructions WIDOS 4001 Page 43 of 59...
  • Page 54 Pan-head screw M10x25 DIN 912 0912J025 Retaining plate whith hole 024402 Retaining plate whith thread 024401 Pan-head screw M10x55 DIN 912 0912J055 Washer M10 DIN 125 0125J Bolt for retaining plate 024404 25.06.2012 Working instructions WIDOS 4001 Page 44 of 59...

  • Page 55: Heating Element

    Spare parts list Chapter 9 Kunststoffschweißtechnik 9.4. Heating element 5 - 8 12 - 13 14 - 15 17 - 20 29 - 35 25.06.12 Working instructions WIDOS 4001 Page 45 of 59...
  • Page 56 Spare parts list Chapter 9 Kunststoffschweißtechnik WIDOS 4001 Heating element Pos. Name Piece Order no. Heating element H 4002, 230 V H4002E Heating plate new HP4002E Heating plate in exchange HPT4002E Stud bolt M 12 HGEW-M12 Grip for heating element...

  • Page 57: Heating Element Holder

    Spare parts list Chapter 9 Kunststoffschweißtechnik 9.5. Heating element holder 6 - 8 9 - 10 2 - 3 13 - 15 4 - 5 25.06.12 Working instructions WIDOS 4001 Page 47 of 59...
  • Page 58 Spare parts list Chapter 9 Kunststoffschweißtechnik WIDOS 4001 Heating element holder Pos. Name Piece Order no. Retaining plate whith thread 024501 Roller 023503 O - ring D18x4 Pan-head screw M10x55 DIN 912 0912J055 Washer M10 DIN 125 0125J Pan-head screw M10x70 DIN 912...

  • Page 59: Conversion Kit For Clamping Tool

    Spare parts list Chapter 9 Kunststoffschweißtechnik 9.6. Conversion kit for clamping tool 1 - 3 4 - 5 8 - 9 10 / 11 25.06.12 Working instructions WIDOS 4001 Page 49 of 59...
  • Page 60 Spare parts list Chapter 9 Kunststoffschweißtechnik WIDOS 4001 Conversion kit for clamping tools Pos. Name Piece Order no. Spindle nut 071109 Thrust washer 023708 Thread spindle 071108 Lock washer size 8 DIN 6799 6799H Rivet for spindle S0425 Set clamping tools OD 450...

  • Page 61: Conversion Kit For Planer

    Spare parts list Chapter 9 Kunststoffschweißtechnik 9.7. Conversion kit for planer 4 - 8 22 - 24 26 - 28 11 - 14 15 - 18 29 - 34 20 - 21 25.06.12 Working instructions WIDOS 4001 Page 51 of 59...
  • Page 62 Spare parts list Chapter 9 Kunststoffschweißtechnik WIDOS 4001 Conversion kit for planer Pos. Name Piece Order no. Ball button C 40 DIN 319 0319C40 Handle bar 040407 Hexagon nut M 16 DIN 934 0934P Claw 023410 Bolt 023408 Guide bolt...

  • Page 63: Conversion Kit For Heating Element

    Spare parts list Chapter 9 Kunststoffschweißtechnik 9.8. Conversion kit for heating element 4 - 5 14 - 15 8 - 10 20 - 22 23 - 25 25.06.12 Working instructions WIDOS 4001 Page 53 of 59...
  • Page 64 Spare parts list Chapter 9 Kunststoffschweißtechnik WIDOS 4001 Conversion kit for heating element Pos. Name Piece Order no. Heating element holder HU4002E Heating plate new HPU4002E Heating plate in exchange HPTU4002E Lifting eye screw M 10 DIN 580 0580J Heat sink...

  • Page 65: Hydraulic Box

    Spare parts list Chapter 9 Kunststoffschweißtechnik 9.9. Hydraulic box 7 - 9 2 - 3 10 - 11 14 - 15 22 - 24 25 - 30 31 - 34 25.06.12 Working instructions WIDOS 4001 Page 55 of 59...
  • Page 66 Fastener for stop-watch 023917 Flat-head screw M 4x10 DIN 965 0965D010 Cylinder knob on request Screw coupling for mini measuring tube VSK02 Screw connection for WIDOS 4001 1010242 O-ring 18x1,5 D18x15 Mini measuring tube V0400140 Hydraulic unit 023203 Accumulator (10 bar)

  • Page 67: Plane Girder For Planing Only At One Side

    Spare parts list Chapter 9 Kunststoffschweißtechnik 9.10. Plane girder for planing only at one side 3 - 4 25.06.12 Working instructions WIDOS 4001 Page 57 of 59...
  • Page 68 Spare parts list Chapter 9 Kunststoffschweißtechnik WIDOS 4001 Plane girder for planing only at one side Pos. Name Piece Order no. Centering bolt 023418 Bearing L51103 Plane girder for planing only at one side 023427 Protective cap (25x25x3) J0205 Washer M 10 DIN 125...

  • Page 69: Declaration Of Conformity

    4. EN 60555, EN 50082, EN 55014 Electromagnetic compatibility The technical documentation is completely available. The working instructions in the language of the user is available. Ditzingen-Heimerdingen, the 25.06.12 Martin Dommer (Technical director) 25.06.12 Working instructions WIDOS 4001 Page 59 of 59...

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